Honda-SOHC

SOHC.co.uk Forums => Project Board => Topic started by: woody928 on May 19, 2020, 11:32:39 PM

Title: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on May 19, 2020, 11:32:39 PM
Well it only seems appropriate to start a proper project thread here following my previous intro a month or so ago. I'm certainly going to have lots of questions for you all as I go! 

Last night I went and collected my 1978 Honda CB550 F1 Super Sport (I believe? Please correct me if this is wrong, I'm a total novice). Does anything look non standard or out of place? It looks like the exhaust is a 'Marshall system' which I'm assuming is a relatively period piece?

The bike has sat in storage for a number of years unused and therefore is in need of some serious TLC. It managed the 35 or so mile ride home however it was very clear that it is in need of some servicing and inspection.

The throttle response was erratic at times, on occasion there was almost a total lack of throttle response. The bike wouldn't climb past 70mph on the motorway and I was having to tinker with the fuel adjustor to lower the idle and keep the bike happy. By the time I got it home I noticed that what I'm assuming are the carb overflow pipes were dropping fuel down onto the ground, the exhaust was popping and banging on overrun so I'm assuming is running rich and on inspection one of the HT leads had dropped onto the manifold and nearly melted through.

I'll be honest and say that I've never worked on bikes before, however I'm mechanically minded and have a workshop manual so intend to crack on and learn as I go. I'm hoping to end up with a reliable bike that can be ridden and enjoyed, originality doesn't bother me as I intend to do some brat/cafe style mods to the bike later down the line with a view to improving performance and changing aesthetics however for now I just want to get it running well and see where I stand.

With the above in mind, I'd be grateful of your thoughts on my current 'to do list'

- Change Oil/Oil Filter
- Replace Air Filter
- Fresh Fuel/ Fuel filter?
- Strip down carbs and rebuild?
- Check timing (never done this before so any guidance appreciate however there's the manuals and YouTube)
- Check valve clearances (never done this before so any guidance appreciate however there's the manuals and YouTube)
- Replace HT leads
- Replace Points
- Flush brake hydraulics
- Front brake rebuild, master too?

Anything I should be adding to that list or further input? Can anyone advise where is a good place to be searching for replacement parts in the UK? are there any good websites for basic consumables?

In particular where to get replacement HT leads and rebuild kits would be useful? I also believe I'm correct in saying I need to be very specific about the make and year of the bike as there were lots of revisions and therefore certain parts/kits won't fit?

Anyway, here's some pictures for you all.

Cheers, Mark

(https://live.staticflickr.com/65535/49914458492_c98dfaceb4_h.jpg) (https://flic.kr/p/2j3LDvW)72DA583C-121C-4630-8110-816CA766A5AA (https://flic.kr/p/2j3LDvW) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49913646278_13c5a6ddac_k.jpg) (https://flic.kr/p/2j3Gu5f)IMG_7623 (https://flic.kr/p/2j3Gu5f) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49914458962_f87fa117ca_k.jpg) (https://flic.kr/p/2j3LDE3)IMG_7618 (https://flic.kr/p/2j3LDE3) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49914458737_81a658d49a_k.jpg) (https://flic.kr/p/2j3LDAa)IMG_7630 (https://flic.kr/p/2j3LDAa) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49914159141_dbde157130_k.jpg) (https://flic.kr/p/2j3K7wH)IMG_7631 (https://flic.kr/p/2j3K7wH) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49914159246_aec11acc17_k.jpg) (https://flic.kr/p/2j3K7yw)IMG_7654 (https://flic.kr/p/2j3K7yw) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49914159181_5631572f5b_k.jpg) (https://flic.kr/p/2j3K7xp)IMG_7656 (https://flic.kr/p/2j3K7xp) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49913646323_1626b80f06_k.jpg) (https://flic.kr/p/2j3Gu62)IMG_7626 (https://flic.kr/p/2j3Gu62) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49914458552_46ac04ade6_k.jpg) (https://flic.kr/p/2j3LDwY)IMG_7651 (https://flic.kr/p/2j3LDwY) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49913646258_ae0bc296cd_k.jpg) (https://flic.kr/p/2j3Gu4U)IMG_7657 (https://flic.kr/p/2j3Gu4U) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: SPR on May 20, 2020, 12:20:56 AM
That looks pretty good as it stands now

Maintenance wise I’m sure the experienced mob will be doing to point you in the right direction :)

Look forward to seeing how you progress

Cheers

Simon 
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on May 20, 2020, 07:41:46 AM
Download the proper Honda manual, you have to start with the 500 and then the 550 "supplements"
Points gap is 0.35mm(14 thou) get feeler gauges with that size in there and spend a lot of time getting the points gap and timing spot on.
DO NOT put a screwdriver in the slot on the end of the camchain tensioner bolt.
If its been stood that long a new drive chain may be a good idea NOT  an O ring type.

Rest is easy------honest
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on May 21, 2020, 09:05:07 PM
That looks pretty good as it stands now

Maintenance wise I’m sure the experienced mob will be doing to point you in the right direction :)

Look forward to seeing how you progress

Thanks Simon :) It looks pretty complete to me, benefits from a recent respray and seems to be a great starting point.

There are a couple of things I can spot that I'd change or correct but as you say originality isn't what your looking for so maybe you'll leave them.

First off yes it's an F1. Green clock faces and flat paint are F1, blue clock faces and metallic paint are F2. The F1 had fork bellows and the F2 didn't.

Your missing the reflectors off the side of the fork ears, saying that your also missing the correct headlight. The shell should be black plastic not chrome and I suspect the OE headlight is bigger as well, should be 7" IIRC. Always better to be seen and be able to see IMO so maybe revert to standard on that one.

The tacho cable appears to be broken, casing has split from the housing near the engine, someone clearly been mucking around in that area as the metal part of the cable shows pliers/grip marks. Be VERY careful removing the cable as it's very easy to break the housing on the engine it locates into, DON'T use an impact driver on the screw holding the cable in place.

There is a thread on site made by Ashimoto on repairing the HT leads on the original coils. Read it and see if you can do it. I've said this before and I'm going to say it again, turn the coils back to front so the HT leads come out of the back, you may need to swap sides on the coils but if your replacing the leads anyway just make them longer and trim down after. Get the leads running over the engine not dangling in the breeze like they are now, saves them shorting out in the rain and also of course getting melted on the exhaust. End cylinders use a long angled HT cap exactly like you got fitted, the inner 2 use a straight long cap.
Should look like this

Flush hydraulics, yes, always a good idea, you've no idea how long it's been in there. Rebuild kit, see how it works first. Remove the caliper and see how the arm it mounts on swings first. Might need some attention as they tend to stick causing brake bind.

Remove rear wheel and check drum lining for cracking, known problem with these bikes. You can get the liner replaced but check first is my advise.

Someone has replaced the left hand switchgear and fitted the wrong one, the UK version has an headlight flasher incorporated into the horn button, yours has the USA version fitted by the look of it, very faded as well so maybe source a new correct version, flasher does come in handy.

Remove the carbs and refurb, use original brass unless damaged. Lots of tips on how to do that on site, just have a good read first.

Change oil and filter, yep, change air filter, check to see how dirty it is first, change points, not unless they are pitted, use original points if possible as aftermarket can cause some timing issues.

Check tappets, yep. Also check camchain tensioner is working. How's the engine sound on tickover? lumpy? a bit noisy like a low down thumping noise?

Lots of advise on here, just heed the experts and you'll soon have her running sweet. Provided of course your prepared to spend a bit of money, parts ain't cheap these days.

Nice example BTW, a very good start by the look of it.

Can I just start by saying a huge thank you for the detailed response!  ;D

That's great to have it confirmed that it is an F1, it should make parts searches infinitely easier.

Thats really interesting, I'll certainly be adding a 7inch headlight to the list then along with a new modern bulb to hopefully brighten things up. I'll be steering clear of chrome as I must admit on the whole I find it a bit much albeit it can also look fantastic.

I've had a look and the tacho cable behind the tachometer is also covered in electrical tape so I suspect its hiding previous bodges. It does however still work so I'll be leaving it for now while more pressing issues are addressed. Thanks for highlighting, are new replacements obtainable?

I've just had a look into this, on the basis of the work involved and also given the coils are an unknown, I'm tempted to just replace with new  items for peace of mind. That's a fantastic idea, no idea why it wasn't done like  that before, I'll get those switched around while I'm in there. Definitely seems like a no brainer to reroute them!

Duly noted, I'll take a less invasive route first and see how it stands. It certainly pulled up on the return home however I have no idea how efficient the brakes were assuming they're in good order. I know we're well behind modern counterparts! I'll check out the rear drum too then.

Is the correct UK version still available anywhere? I wouldn't even know what it would look like however I must admit it did look very odd as a pairing, a flasher could come in very handy!

Carbs are going to be my biggest initial challenge I imagine, I've been watching a video of a teardown by classic octane on youtube. I think it will be like my bible through out the process.

Noted on the service items, will proceed as such.

Those  are two new skills  I'm going to have to read up on and learn. I fired up the bike this  evening having stat it since I've been home. Clearly it wasn't getting enough fuel with current settings now that it's cold. Urm it sounds very noisy to me and far from healthy compared to before now however I'll defer to all of your experience and judgement.

https://youtu.be/KYzUYmTbiPk

I've realised that money will need to be spent however I'm keeping my fingers crossed that its far more affordable than my cars have been! I fear theres lots of jobs to do before getting on to fun modifications, the joys of classic motoring! 

Thanks again for all of your input, its invaluable!  8)

Download the proper Honda manual, you have to start with the 500 and then the 550 "supplements"
Points gap is 0.35mm(14 thou) get feeler gauges with that size in there and spend a lot of time getting the points gap and timing spot on.
DO NOT put a screwdriver in the slot on the end of the camchain tensioner bolt.
If its been stood that long a new drive chain may be a good idea NOT  an O ring type.

Rest is easy------honest

Thanks Bryan, I've found a few  in Aladdins cave and have begun reading thank you, certainly two things I'm going to have to learn to do. I fear that part will be a steep learning curve.

I'll keep this in mind, is there any reason I'd be tempted to do so? (showing total ignorance)

Would you recommend the X type chain instead, it could be a  good idea for peace of mind?
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Trigger on May 22, 2020, 06:01:01 AM
I have a 500 which has been converted to all the electrics off a CB550F2. The F1 and F2 are virtually identical on electrics. I've just bought a brand new L/H switchgear with passing switch so I'll post a pic of it for you when I can find it again. It may be for sale as I've completely restored my old one and I'm happy to use that for now. Be aware that some parts are cheap and others seem to be vastly inflated, it depends on how many are still sat on shelves I think. If it's very rare be prepared to pay over the odds for the part, petrol tanks NOS are very expensive and a genuine new 550 silencer will set you back and arm and a leg IF you can find one.

The black headlight bowl is readily available but be sure it's off a 550 as the 500 is deeper and won't fit due to the handlebar mounted ignition switch on the 550. The 550 is shallower as the handlebar switch wires go down under the tank and not into the headlight like on the 500. Headlights are easy to find as a rule, try and find a good 7" Cibie if you can as they are really good. I had one around a while ago brand new but no idea where it is now. If I find it I'll let you know.

Tacho cable is easy to find and replace.

Some bad and good reports on the David Silver coil replacements, I prefer to stay standard and it's cheaper to fix the old ones than buy new. The coils are usually fine, it's the leads that fail.

Some controversy now, everyone says DON'T fit an O ring chain on the 500/550 but I ran one for years and it was fine. The problem is that the O ring chain is wider than the standard chain and the link pins gouge into the crankcase where the front sprocket fits. This is true, however it's really only true IMO if you use a 530 O ring chain, the pins are longer. The standard chain supplied from new was a DID 50 chain with split link, this had a pin length of 21.9 according to the DID website, this is 0.8622 inches, (for some reason DID list the existing chain dimensions in inches and the old style chain in MM), a 530 chain has a pin length of 0.963 for an O ring and 0.931 for an X ring chain (O ring and X ring chains are the same except for how the rivet is riveted) so you can see it's much wider, however the 525 O ring chain has a pin length of 0.886 for O ring and 0.866 for X ring, so almost identical to the standard 50 chain. The O ring chain I ran was off a CBX550 which is the same chain as the CB650, the odd thing is if you try and buy an original chain off CMS you can only buy an O ring chain now, funnily enough the same as the CBX550/CB650. Take for that whatever you want,  I'll be running an X ring on mine when it's finally restored. Odd but DID list a vintage bike chain in O ring and it's the 525


Not all headlight bowls for the 550 are the same. The early 550 K0,K1,K2 are the same as the 500/750.

There is a 500F1/F2 headlight bowl >>> https://www.ebay.co.uk/itm/Honda-CB550-F1-F2-SOHC-Headlight-bowl-61301-375-003B/164134785053?epid=675479719&hash=item263732101d:g:tn0AAOSwOM5edy6A

Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on May 23, 2020, 04:20:45 PM
I have a 500 which has been converted to all the electrics off a CB550F2. The F1 and F2 are virtually identical on electrics. I've just bought a brand new L/H switchgear with passing switch so I'll post a pic of it for you when I can find it again. It may be for sale as I've completely restored my old one and I'm happy to use that for now. Be aware that some parts are cheap and others seem to be vastly inflated, it depends on how many are still sat on shelves I think. If it's very rare be prepared to pay over the odds for the part, petrol tanks NOS are very expensive and a genuine new 550 silencer will set you back and arm and a leg IF you can find one.

The black headlight bowl is readily available but be sure it's off a 550 as the 500 is deeper and won't fit due to the handlebar mounted ignition switch on the 550. The 550 is shallower as the handlebar switch wires go down under the tank and not into the headlight like on the 500. Headlights are easy to find as a rule, try and find a good 7" Cibie if you can as they are really good. I had one around a while ago brand new but no idea where it is now. If I find it I'll let you know.

Tacho cable is easy to find and replace.

Some bad and good reports on the David Silver coil replacements, I prefer to stay standard and it's cheaper to fix the old ones than buy new. The coils are usually fine, it's the leads that fail.

Some controversy now, everyone says DON'T fit an O ring chain on the 500/550 but I ran one for years and it was fine. The problem is that the O ring chain is wider than the standard chain and the link pins gouge into the crankcase where the front sprocket fits. This is true, however it's really only true IMO if you use a 530 O ring chain, the pins are longer. The standard chain supplied from new was a DID 50 chain with split link, this had a pin length of 21.9 according to the DID website, this is 0.8622 inches, (for some reason DID list the existing chain dimensions in inches and the old style chain in MM), a 530 chain has a pin length of 0.963 for an O ring and 0.931 for an X ring chain (O ring and X ring chains are the same except for how the rivet is riveted) so you can see it's much wider, however the 525 O ring chain has a pin length of 0.886 for O ring and 0.866 for X ring, so almost identical to the standard 50 chain. The O ring chain I ran was off a CBX550 which is the same chain as the CB650, the odd thing is if you try and buy an original chain off CMS you can only buy an O ring chain now, funnily enough the same as the CBX550/CB650. Take for that whatever you want,  I'll be running an X ring on mine when it's finally restored. Odd but DID list a vintage bike chain in O ring and it's the 525

That would be really helpful, if you do find it and are happy to sell it then please do let me know, however a picture either way would be very helpful! That makes a lot of sense, fortunately for me items like those two items referenced  are less of a concern given my disposition to resto modding older vehicles, I'm doing my best to navigate the minefield of options.

Thanks again, that makes a lot more sense now. I'll be keeping my eye out while I work out what to do, my main goal is to spend funds on going it up and running reliably first before moving onto other items, however a decent headlight will be high up the list! Do these headlights use H4  bulbs or can they be modified to use them?

Found and ordered one now thanks. I've looked at the lead replacement guide and really don't fancy cutting the originals to pieces right now, its a  job I'll contemplate later so have just gone for replacement  items.

Wow, another learning curve there. Duly noted, I'm going to leave the chain for now while everything else is sorted however I would imagine I'll be going down the X ring route as and when I get there. Amazing that such small variations can cause damage to the crank case. 

Not all headlight bowls for the 550 are the same. The early 550 K0,K1,K2 are the same as the 500/750.

There is a 500F1/F2 headlight bowl >>> https://www.ebay.co.uk/itm/Honda-CB550-F1-F2-SOHC-Headlight-bowl-61301-375-003B/164134785053?epid=675479719&hash=item263732101d:g:tn0AAOSwOM5edy6A

Thanks, good to know what I'm looking for. It's now in my watch list.

Well its been a busy and expensive day ordering lots of service items and replacement parts. I've also bitten the bullet and finally ordered an Ultrasonic cleaner to assist with my carb rebuild. Fingers crossed I'll be starting to pull things apart and replace from next week.

On the subject of carb rebuilding, is anyone able to provide an insight on the rebuild kits available? I've seen the following two:

https://www.davidsilverspares.co.uk/CB550F1-SUPER-SPORT-1976/part_28930/

https://www.wemoto.com/bikes/honda/cb_550_f_f1_f2/75-80/picture/carburettor_complete_repair_kit

Alternatively and noting the advice to maintain the original brass components would I be better off with one of these complete gasket kits? Looking at the above two options there would appear to be lots of O-rings missing compared to the OEM option listed below?

https://www.davidsilverspares.co.uk/CB550F1-SUPER-SPORT-1976/part_4946/

Finally did anyone have any thoughts on the sound of the bike per the video below? (Certainly concerned that its noisy)

https://www.youtube.com/watch?v=KYzUYmTbiPk
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Nurse Julie on May 23, 2020, 04:41:24 PM
It's really difficult to hear engine noises properly on a mobile phone video but it doesn't sound like it's firing on all 4 cylinders and it sound like either the cam chain is rattling, or the primary chain or both. But like I say, videos can be really deceiving.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on May 23, 2020, 04:42:19 PM
You can get all the O rings for the carbs in a kit from Julie on here, the paper gasket is usually OK
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on May 23, 2020, 10:01:36 PM
It's really difficult to hear engine noises properly on a mobile phone video but it doesn't sound like it's firing on all 4 cylinders and it sound like either the cam chain is rattling, or the primary chain or both. But like I say, videos can be really deceiving.

Very true, it was more the rattle is what had me worried. Perhaps I should start with the cam chain adjustor as I imagine I'd have to open things up otherwise. Not firing properly would be explained by the melted plug lead and also what I discovered this evening. I could also use some new screws looking at the ham fisted efforts of a previous owner...

My points look pretty knackered and one has quite a large gap, I definitely need to get on with servicing and making factory adjustments before guessing where I really stand.

(https://live.staticflickr.com/65535/49927850467_8aa7e023c8_k.jpg) (https://flic.kr/p/2j4Xhu4)IMG_7707 (https://flic.kr/p/2j4Xhu4) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49927850352_697a3901a0_k.jpg) (https://flic.kr/p/2j4Xhs5)IMG_7708 (https://flic.kr/p/2j4Xhs5) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/49927850307_5fbce8d3e4_k.jpg) (https://flic.kr/p/2j4Xhri)IMG_7710 (https://flic.kr/p/2j4Xhri) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Whats the recommendation with replacement points? Are aftermarket options ok or do I need to stick with the more expensive OEM option?

You can get all the O rings for the carbs in a kit from Julie on here, the paper gasket is usually OK

Thanks, presume you're referring to the same helpful Julie above? Any other advice on the rebuild kits?
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: K2-K6 on May 23, 2020, 11:31:47 PM
If no headlight available from the forum,  these are good alternative  https://www.autoelectricsupplies.co.uk/mobile/product/986

Take H4 bulb of your choice, I use phillips white vision in them.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on May 24, 2020, 06:55:26 AM
Now i have a diamond file to cure those points, you used to be able to get disposable flexi contact files.
It takes quite a bit of time and practice to get both the points gap(0.35mm) and the timing spot on the F as the gap alters when you move the plate and the timing alters with gap but getting it spot on is worth it.
As to the screws you get the standard answer "they are all like that sir" BECAUSE people use phillips screwdrivers instead of jis ones!
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on May 24, 2020, 03:08:31 PM
If no headlight available from the forum,  these are good alternative  https://www.autoelectricsupplies.co.uk/mobile/product/986

Take H4 bulb of your choice, I use phillips white vision in them.

Thanks for the link, that could be that I piece something together myself. I could use the plate linked above, one of these headlights and then pickup a surround too. It would certainly be a great upgrade, I'm a big fan of the Osram Nightbreaker Lazer range myself  :)

Now i have a diamond file to cure those points, you used to be able to get disposable flexi contact files.
It takes quite a bit of time and practice to get both the points gap(0.35mm) and the timing spot on the F as the gap alters when you move the plate and the timing alters with gap but getting it spot on is worth it.
As to the screws you get the standard answer "they are all like that sir" BECAUSE people use phillips screwdrivers instead of jis ones!

I'll go off and see what can be found, some small files for the collection could be invaluable. Being a novice I've been watching some extremely helpful youtube videos however I know there is going to be a lot of trial and error!

 :'( I'm getting that impression, I'll confess I'd never heard of JIS screwdrivers before I bought the bike however they were my first purchase!

What's worrying about the pics of the points plate is that the wires are exposed on the condensers, they must be aftermarket as genuine Honda ones are potted on the end where the wire comes out. There is a risk of getting a shock with the wires exposed like that and I have to say as someone who's had more than a few belts from a charged condenser it's not a little belt either.

I'd imagine all the threads are now ruined on the 2.3 plate screw holes as those are most likely imperial screws and probably bigger than the original threads.

I found a complete points plate the other day lurking in a box in the shed, screws are in reasonable nick, PM me your address and I'll send it down as soon as I can get to the Post Office, genuine condensers and the points are in better condition as well. Plus it has a proper felt pad for lubing the advance/retard mechanism, that looks to be a piece of carpet.

 ;D Honestly I'll bite your arm off with that offer! I'd been contemplating dropping a bomb on a Dynatek electronic ignition before that just to be done with. Thank you so much, PM now sent!  8)

Thanks for the warning, I won't be firing up the ignition again right now as it stands. All basic service items had been ordered with the exception of this area so it'll all get ripped out and replaced for peace of mind before attempting to start up again. As you say it looks like a mess  :'(

I think what concerns me the most is the ham fisted repairs and 'maintenance' clearly carried out by the previous, previous owner. I just hope this isn't the tip of the iceburg. I'm just itching to get stuck in and get it sorted to get back out on the road again, I suppose its a miracle that the bike even managed the 40 odd mile ride home all things considered. 
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on May 24, 2020, 04:21:03 PM
A lot of failures reported with Dyna on US board
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on May 26, 2020, 12:32:48 PM
A lot of failures reported with Dyna on US board

Thanks for the warning, nothing seems perfect it seems.

Might be a couple of days or so before I post the points plate, need to clean it up a little as it's full of oily crap from the box it was in and I want to replace all the screws with new ones as even though they are pretty good it would be better if they were new. Won't have the electrical lead on it as I want that so muck around with but you can transfer your old one over no problem.

No worries, I doubt it will be till next weekend that everything else will have been sorted in order to start up agin to see where I stand before  tackling the carbs. Much appreciated that you're also taking the time to make it fully ship shape before sending it over! That's absolutely fine, I've not looked but would assume its a straightforward swap.

Found a left hand switchgear if your interested.

This is what you currently have.

https://www.ebay.co.uk/itm/Handlebar-Switch-Turn-Signal-Left-For-Honda-CB-750-Four-K3-K6-550-360-400/184298717193?hash=item2ae90f4009:g:E1IAAOSwS8heyinx

And this is what you should have

https://www.ebay.co.uk/itm/Handlebar-Switch-Turn-Signal-Left-For-Honda-CB-400-500-K2-550-750K3-K6-Four/184285762361?hash=item2ae8499339:g:KQwAAOSwhrFeyipy

You can see the difference in the horn button arrangement.

Those are both copies BTW, they sell pretty cheap because of the quality of the switches inside IMO, not knocking them for what they are and if that's all you can get then they are worth having.

I have a genuine Honda one, in good condition, paint is still pretty black ( they do fade after a while even if kept indoors) all the bullet connectors are in good nick, no cut or soldered wires etc. I can test all the switches work etc. £45 inc P&P.

Thanks for sharing and updating me, it now makes a lot more sense. You really have a keen eye to have spotted that! Ping me across your paypal details and I'll send you the money over :) Hopefully that's a straightforward case of just plugging the right bits in, nice that its an OEM quality piece too! Would certainly give some extra functionality and actually looks like one of the nicer OEM pieces to keep for my build. You'll get tired of hearing me saying thank you, however thanks yet again!   ;D

Hopefully that can go with the points plate to save you on postage too.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: SteveW on May 26, 2020, 01:56:41 PM
On the subject of electronic ignition, I got mine from David Silvers. Have done over a 1000 miles on it and its never missed a beat.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: JamesH on May 26, 2020, 07:54:06 PM
On the subject of electronic ignition, I got mine from David Silvers. Have done over a 1000 miles on it and its never missed a beat.
I've started using the DSS electronic ignition system and it's actually an excellent quality item. I believe this is the 'Daytona' system made in Japan by Kokusan - interestingly they are the OEM manufacturer of the electronic ignition in my 1979 Kawasaki KZ1000 MkII.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on May 26, 2020, 08:39:15 PM
Kokusan made a lot of electrical stuff for many japanese motor manufacturers
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on May 27, 2020, 07:37:40 AM
2nd for Mark(hondamans) system because i do so little mileage i live with the points as is but if i was riding more i would go with his.
He is that honourable that when a two year old system failed he replaced it evev though the problem was where the owner mounted it and managed to fill it with water.
Similar to the old sparkrite system for cars where it drops the current accross points to milliamps so no arcing or electrical wear, plus if it does go wrong a matter or minutes to revert to standard, unlike full ellectronic systems
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: K2-K6 on May 27, 2020, 07:37:38 PM
"Similar to the old sparkrite system for cars" that's a good memory of those Bryan.

I've still got a Sparkrite fitted to a 1980 Rover V8 with single set of points for all 8 cylinders. Still works perfectly and has a switch so that you can isolate it and run just points or switch it to electronic without changing any hardware.  Works so well you can start it by hand hot or cold with the crank handle  ;D

They are just taking the timing from the points with a miniscule load across then,  then using an amplifier to switch a power transistor to run the coils.  The points really do last indefinitely with this method as all the loads are switched via solid state components.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on May 30, 2020, 01:50:07 PM
Thanks for all of the insight chaps, there certainly seem to be some good systems and choices out there.

Ken has very generously offered me a solution to replace the mess on my bike and get me up and running. I think I'll need to take the time to look into Honda Mans system too, it sounds like a great compromise between the two.

I have plans to ride the bike over to the Netherlands and West Germany to visit some travelling friends once I've got the  bike roadworthy and the world has opened back  up a little more, so I'm working to the goal of making her ready for a 1000 mile trip after languishing in storage for all of these years.

Some parts are finally starting to turn up on the  doorstep so I need to get cracking. I've even picked up a 6L ultrasonic cleaner to do justice to the carbs when  I get around to stripping them. I still need to work out what the best service kit for my rebuild will be. Perhaps considering all of the required O-rings from Julie and then hoping that all of the internal components can come up like new in the ultrasonic...
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 01, 2020, 09:01:19 PM
Just a small update, parts are trickling in slowly and I'm waiting on a big order from Wemoto before I can really get cracking. 

My new coils have arrived so I was replacing those before I discovered that all four retaining screws were knackered with rounded off heads so I had to fight all of those off first. Next hurdle was that the positive wires had been fitted with spade connectors (I assume these were bullet connectors from factory) and had two spades forced into one positive wire. I've purchased a dual bullet connector adapter to replace this and hopefully get the new coils all wired in and secured. I have full intentions of reversing them from the factory placement to run the ignition wires via the engine rather than down by the exhaust manifold as before causing my melting issues.

Today I also got out there with a set of feeler gauges to check and adjust the valve clearances, I think I've got these right now however getting just the right amount of drag on the feeler gauges must be an art I'm sure. We'll see soon enough. 

As ever, the more I look into a project like this, there's more to be done. A new chain will be going on having noted surface rust on the one fitted, at the same time new sprockets seem like a wise idea. Does anyone have any recommendations? I've seen the following two x-ring type kits which looks reasonable...

https://www.wemoto.com/bikes/honda/cb_550_f_f1_f2/75-80/picture/swift_super_heavy_duty_black_silver_x-ring_chain_and_jt_sprocket_kit

https://www.wemoto.com/bikes/honda/cb_550_f_f1_f2/75-80/picture/did_vx_heavy_duty_x-ring_gold_and_black_chain_and_jt_sprocket_kit
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 01, 2020, 10:29:09 PM
Some more good news for you as well then Woody. Replacement screws for the points plate arrived today. Swapped over and trimmed them down as they were a trifle too long and I was worried the advance/retard mechanism might just hit them. The switchgear and the points plate will be in the post tomorrow buddy. Amazing how well the plate looks with brand new screws. You should be able to use the points on them but see if the condensers are still ok. You'll know as soon as you start the bike if they are, the wires on them are kinda hard these days but then again they are at least 40 years old.

As for chain, if you can hang on a few days I'll measure the pin length on the O-Ring chain I used for years, it was still on the bike when I took it out of storage. You can compare pin length on that to the newer X ring chains.

Fantastic, thanks Ken thats really appreciated! Very much looking forward to getting that fitted up in place of the tired unit in there so that I can actually set the ignition timing! Next stop after that will be a start up again to see where I stand before stripping the carbs and starting that rebuild. I'll keep my fingers crossed it fires up ok, if the condensors have seen better days, what will the obvious signs be? (showing my ignorance again)

I'm not in a rush on that front given the list of other jobs I already have so can easily hold off for a few days. That would be much appreciated  ;D
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 03, 2020, 08:39:12 PM
On it's way Woody, 1st class signed for. When it arrives don't forget to put some fresh oil on the felt pad for the advance/retard mechanism to run against, or the heels on the points will wear down fast.

Thanks Ken 8) That's great news, I had a decent delivery from Wemoto today, new JIS screws arrived for the coils and Julie has sorted me out with a carb rebuild gasket kit so I'm moving in the right direction! What oil would you advise using showing my ignorance again? 

Noting your wisdom on the condenser front and the exposed wires in mine, I've just ordered a new pair to fit at the same time. Fingers crossed that buys me some reliability and I won't have to worry for a long time. 

I'm also keeping fingers crossed that the weather holds out and its going to be a  very productive weekend  ;D
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on June 04, 2020, 08:50:26 AM
Most motor factors will sell a mineral oil, you may have to get 15w40 instead of 10w40 but thats fine. My local place(try not yo use eurocarparts) charge £15.46 plus vat for 5ltr, just dont say its for a motorcycle or they get worried as they dont have recommendations for that tell them its an old Ford or Vauxhall.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 04, 2020, 04:27:57 PM
I've picked this up for the engine the other day so I should be good, £18 on sale. Whats the oil capacity on these? I think I read somewhere that it's 3.2L.

https://www.eurocarparts.com/p/shell-helix-hx7-10w-40-5ltr-521772251

I presume I can use the same oil on the the ignition plates felt pad to lubricate it?   
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on June 04, 2020, 04:57:59 PM
Worries me it is semi synthetic listed for a car so may have friction inhibiters that wont do clutch any good
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Trigger on June 04, 2020, 05:51:43 PM
I've picked this up for the engine the other day so I should be good, £18 on sale. Whats the oil capacity on these? I think I read somewhere that it's 3.2L.

https://www.eurocarparts.com/p/shell-helix-hx7-10w-40-5ltr-521772251

I presume I can use the same oil on the the ignition plates felt pad to lubricate it?

I would not use that oil on a motorcycle. It is the wrong spec for a engine with combined clutch and gearbox. 
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 04, 2020, 06:04:29 PM
Oops... I just fully read the specs  :-\

What would you guys recommend for these bikes?
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Oggie400F on June 04, 2020, 07:48:44 PM
Most motor factors will sell a mineral oil, you may have to get 15w40 instead of 10w40 but thats fine. My local place(try not yo use eurocarparts) charge £15.46 plus vat for 5ltr, just dont say its for a motorcycle or they get worried as they dont have recommendations for that tell them its an old Ford or Vauxhall.

Is this oil the correct spec mineral oil for the SOHC’s?

https://www.ebay.co.uk/itm/303176095119

Not a bad price for the 20 litres and free delivery. 🤔
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on June 04, 2020, 08:05:29 PM
Well i just bought some
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: K2-K6 on June 04, 2020, 08:19:47 PM
To cut through the shell marketing bullox,  those two are more or less the same spec as each other.

They both meet diesel rating of CF too.

The statement for the shell " uses both mineral and synthetic base stock" is more or less there to justify a higher price.

Neirher should give a problem,  bulk is significantly cheaper to by if you're going to use the quantity.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 04, 2020, 09:17:03 PM
To cut through the shell marketing bullox,  those two are more or less the same spec as each other.

They both meet diesel rating of CF too.

The statement for the shell " uses both mineral and synthetic base stock" is more or less there to justify a higher price.

Neirher should give a problem,  bulk is significantly cheaper to by if you're going to use the quantity.

So I'm still ok to use the shell oil and don't need to rush off to the shops then? Long term it would certainly make sense for me to invest in a larger quantity supply, good point well presented!

Just seen that you're in Wimbledon, you must only be about 15-20 mins up the road from me in Hinchley Wood. Do you get out on your bike often? It would be great to compare notes with some other owners and kick tyres at some point.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: K2-K6 on June 04, 2020, 10:23:37 PM
I'd be comfortable using that in a Honda bike engine,  although realise that opinions can vary considerably on such a subject  :D

"Shell Helix HX7 10W-40 - 5Ltr
Shell Helix HX7 with its unique cleansing technology, goes on cleansing and protecting to help keep your engine clean and running efficiently. Formulated with synthetic technology, Shell Helix HX7 makes use of both synthetic and mineral base stocks to achieve higher performance levels than can be formulated from mineral oils alone. It provides excellent resistance to degradation to help maintain protection throughout the oil-drain interval. It also helps to reduce evaporation to help provide low oil consumption"

That part about "synthetic technology " is really kind of code for it's not really synthetic at all  ;D

It's a basic good quality,  correct viscosity oil that's suitable.  Better I'd not make it too much of an oil thread I suppose.

Location,  yes we're often around and passing you not so many times as I'd like on the bike though.  I usually stop by Newlands corner if near for a bike fix though on a weekend.
I'm fine to meet up though for a general natter about these old bikes,  or help / assistance if you needed to get heads together on anything. It's good seeing them out and running well.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 07, 2020, 11:36:19 PM
I'd be comfortable using that in a Honda bike engine,  although realise that opinions can vary considerably on such a subject  :D

"Shell Helix HX7 10W-40 - 5Ltr
Shell Helix HX7 with its unique cleansing technology, goes on cleansing and protecting to help keep your engine clean and running efficiently. Formulated with synthetic technology, Shell Helix HX7 makes use of both synthetic and mineral base stocks to achieve higher performance levels than can be formulated from mineral oils alone. It provides excellent resistance to degradation to help maintain protection throughout the oil-drain interval. It also helps to reduce evaporation to help provide low oil consumption"

That part about "synthetic technology " is really kind of code for it's not really synthetic at all  ;D

It's a basic good quality,  correct viscosity oil that's suitable.  Better I'd not make it too much of an oil thread I suppose.

Location,  yes we're often around and passing you not so many times as I'd like on the bike though.  I usually stop by Newlands corner if near for a bike fix though on a weekend.
I'm fine to meet up though for a general natter about these old bikes,  or help / assistance if you needed to get heads together on anything. It's good seeing them out and running well.

There's always opinions on everything, you've made me stop doubting myself though so thank you. It's going in when I get to it.

It seems we're never out on two wheels quite as much as we'd like. I was up at Newlands corner a couple of times when training for my license however I'm yet to get up there on my own two wheels. Hopefully when its all done and more acceptable then I can say hello up there! 

Be careful, I may well take you up on that :) I'm sure I'll hit some headaches when it comes to carb tuning as smooth running as that really isn't my forte. I'm keeping fingers crossed that my missing ignition components turn up this week to allow me to crack on with next weekend.

On the note of ignition components I'm replacing the coils. I know that when sitting on the bike, the left coil goes to cylinders 1 & 4 and the right coil goes to cylinders 2 & 3 however does it matter which wire goes to which cylinder from the respective coil?

I know on cars it matters which HT lead goes to which cylinder but am imagining its not critical on the bike given its coming from a coil instead? Please correct me if my assumption is incorrect as I don't wish to go cutting leads to size only to get it wrong...
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 08, 2020, 11:31:45 PM
So long as the leads go to either cylinder 1 or 4 and that's from the 1-4 coil then no, same applies to the 2-3 coil, either lead to either 2 or 3. You may find however that one lead will reach and the other may not, if either reach I'd advise not to trim them unless the lead is really long, you can always cut away but you can't add.  Honda use what's called a wasted spark system so both lead will fire when the points open not just one like a car.

Any sign of the points plate and switch yet Woody, I have the tracking receipt in my pocket and I want to know if I can throw it.

Thanks for confirming Ken, that keeps things nice and simple! I must admit that I'd intended to cut them just to tidy things up however I do see the argument for just stashing the extra lead away. Interesting, its amazing how things are very similar but very different. It continues to be a learning curve! New screws and connections are now here so I'm hoping to get those plumbed in and the plugs changed this week.

I was pleased to find your parcel when I got home this evening along with my new condensers rather conveniently. The packaging was mega thank you, and the handlebar switch is in superb condition for its age! That will make quite the difference once its been installed, I'm just naively hoping to find all of the original connections still in place to hook it all up. Thank you very much for this.

I'm hoping that this week I'll be cracking on with the ignition and carbs in anger so stay tuned for some updates. 
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 12, 2020, 07:37:05 PM
Pretty sure the loom connections will be fine, there are in a small box just below the coils, watch the screw holding the lid on, it rounds off for fun if your not careful. Drop some grease on the threads when you refit it.

Considering the parcel was posted first class signed for that's not good service from the PO, should have been with you well before that.

I'm keeping my fingers crossed! I know the one, its been out to give me access to the coils which have now been replaced and  the new cables rerouted. Fortunately mine has come out ok, I'll certainly give it some TLC though. It looks like the weather is finally going to give me a break this  weekend so I can finally get cracking so hopefully some positive updates to follow. 

You're parcel wasn't the only one delayed through RM, they're clearly struggling but thankfully it arrived safe!
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 14, 2020, 05:05:44 PM
Well its fair to say its been a very busy weekend and finally some serious progress made.

The new coils have been fitted up and replaced, two spark plugs replaced (I'm waiting on a thin-wall socket to get to the other two), refurbed points plate fitted up and static timing set. I tried to adjust the cam chain tensioner and followed all of the steps however the adjuster when loosened didn't really seem to snap back when turned using a flat head screwdriver. That one seemed very odd so I just nipped it back up and got the bike running to check how we were running and I've back to firing on all four cylinders and sounding a little healthier albeit clearly with serious fuelling issues.

With this done it was time to get cracking and get the carbs out and stripped to be rebuilt. Fuelling is clearly a big issue to running as when the  engine is revved there's all kinds of confusion and hesitation with revs rising and falling of their own accord. Getting the carbs out  proved simple enough however it's clear that all of the jubilee style fasteners used are well past their best. More rounded screw heads and very tired looking metal. I'm looking to replace the lot with new stainless versions once I've got them measured up. If anyone has any recommendations though then I'm all ears.

(https://live.staticflickr.com/65535/50005522451_3453a41b77_h.jpg) (https://flic.kr/p/2jbPnEc)IMG_8020 (https://flic.kr/p/2jbPnEc) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50004996408_27951dc16c_h.jpg) (https://flic.kr/p/2jbLFhu)IMG_8024 (https://flic.kr/p/2jbLFhu) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005522211_8a985900ad_h.jpg) (https://flic.kr/p/2jbPnA4)IMG_8029 (https://flic.kr/p/2jbPnA4) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Carbs taken into the workshop and on the bench and it's been the meticulous job of totally stripping them down piece by piece and checking for wear while keeping each carb separated for reassembly. The below linked video by classic octane has been my bible, honestly Taylor is the man who's made this possible, his guidance is phenomenal!

https://www.youtube.com/watch?v=JFTOfYl5BSc

Last night I spent countless hours getting to the point that each carb was fully stripped to its bare bones. I've documented a number of screws which have seen far better days and am ordering stainless replacements so that there's new fixings where appropriate. It goes without saying that these have been stripped before, with several bodges along the way... The bottom float bowls for example each now appears to have been re-drilled and tapped with at least one securing M5 securing Allan headed bolt in place of the factory M4 JIS screws. No idea why, however now I have no choice but to go with it. 

It also appears that someone attempted some zinc plating a long time ago with very mixed results however now I'll be left with the bodies finished in raw metal form and caps and float bowls in faded zinc plate but that's the way it goes.

(https://live.staticflickr.com/65535/50005781087_5baa98c9a5_h.jpg) (https://flic.kr/p/2jbQGxr)IMG_8050 (https://flic.kr/p/2jbQGxr) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

The fuel could have looked a lot better, its certainly fairly dark I think. Is this due to rust from the fuel tank? Something to be looked at? I'll certainly be refilling with fresh fuel before going anywhere.

(https://live.staticflickr.com/65535/50005521906_2d32346e53_h.jpg) (https://flic.kr/p/2jbPnuN)IMG_8040 (https://flic.kr/p/2jbPnuN) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

It also comes as no surprise that all of the fuel lines were petrified and just plain dangerous in places, the years certainly haven't been kind to the fuel lines, once of which literally broke off around the jubilee clip. You do wonder when this job was last done.... I now need to ascertain the correct pipe sizes to get these ordered.

With everything stripped down I've put my new 6L Ultrasonic cleaner to good use and put each carb and its fully assembly through on a 30 minute cycle at around 65 degrees with a carb cleaner solution. Following this each carb has been individually cleaned by hand, all channels checked for clearance with compressed air to make sure there were no obstructions and all brass components polished up or wet and dry sanded in the case of the carb float pins to get them sliding through nicely again. There were some small battles with removing the needles as the screws were locked in place and needed a heavy dousing of Plus Gas to get cracked, one screw still rounded its head but still came out thankfully. My first purchase of magnetic JIS screwdrivers has honestly been worth its weight in gold, they're incredible!

At this stage I think functionally everything is as good as it can be now. I've been really impressed by the cleaning results from this, the water colour and dirt its taken off was pretty shocking!

(https://live.staticflickr.com/65535/50005521591_22d7e8ca29_h.jpg) (https://flic.kr/p/2jbPnpn)IMG_8093 (https://flic.kr/p/2jbPnpn) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50004994958_7c31a9e03a_h.jpg) (https://flic.kr/p/2jbLERu)IMG_8055 (https://flic.kr/p/2jbLERu) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005780227_24a5c10318_h.jpg) (https://flic.kr/p/2jbQGhB)IMG_8059 (https://flic.kr/p/2jbQGhB) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005780087_2dad6eb9fa_h.jpg) (https://flic.kr/p/2jbQGfc)IMG_8068 (https://flic.kr/p/2jbQGfc) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005521786_76c3341812_h.jpg) (https://flic.kr/p/2jbPnsJ)IMG_8082 (https://flic.kr/p/2jbPnsJ) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005521641_b04674a4b8_h.jpg) (https://flic.kr/p/2jbPnqe)IMG_8084 (https://flic.kr/p/2jbPnqe) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005779942_0681ada610_h.jpg) (https://flic.kr/p/2jbQGcG)IMG_8085 (https://flic.kr/p/2jbQGcG) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50004995418_1545e133ec_h.jpg) (https://flic.kr/p/2jbLEZq)IMG_8096 (https://flic.kr/p/2jbLEZq) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

I noted that these tabs on both sides were bent on disassembly, I've hammered them flat again however one is now showing a hairline crack which concerns me somewhat. Any idea what these are and how crucial this tab is? I'd have no idea where to find a replacement  :-[

(https://live.staticflickr.com/65535/50005780167_bf2003ab4b_h.jpg) (https://flic.kr/p/2jbQGgz)IMG_8062 (https://flic.kr/p/2jbQGgz) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Next steps are sourcing replacement items where appropriate having measured everything up. In terms of screws I've come across MrMegaPack.co.uk which seems to have a huge selection of fittings for our bikes and am putting in an order for one of their 'Megapacks' which will give me all of the commonly needed screws to hand in stock going forward.

I would be very grateful of some assistance with regards to jetting and needles as I have no idea if what I have fitted is factory or changed and whether any adjustments should be replaced. Looking at least one of the secondary jets it appears to have previously been mauled and damaged in a few areas so should at the very least be replaced.

(https://live.staticflickr.com/65535/50004994558_edcb31fbd6_h.jpg) (https://flic.kr/p/2jbLEJA)IMG_8099 (https://flic.kr/p/2jbLEJA) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005520806_7deb2fc362_c.jpg) (https://flic.kr/p/2jbPnaQ)IMG_8100 (https://flic.kr/p/2jbPnaQ) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Currently though it was running:

98 - Main Jets
38 - Secondary Jets
273004 - Needles (needle height was set one ring down from the highest adjustment point)

I intend to keep using the stock airbox and the bike has fitted a 4-1 system with a Marshall muffler at the rear. I'd like to eventually replace this however for now its what I'll be running and need to bear in mind for my setup. Do the above size jets and needles sound correct? Should I been looking at other needles or jets?

Does anyone know where replacement jets can be sourced? At the very least one should be replaced... 

Below are the pics of where I started to where I currently stand, lots of progress made however clearly lots of work still required for reassembly and setup once all of the requisite items and sourced and refitted. Any observations or input gratefully received  :D

(https://live.staticflickr.com/65535/50004995278_5028c317e4_h.jpg) (https://flic.kr/p/2jbLEX1)IMG_8105 (https://flic.kr/p/2jbLEX1) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005521356_2ca0d56ea1_h.jpg) (https://flic.kr/p/2jbPnkj)IMG_8107 (https://flic.kr/p/2jbPnkj) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005779782_4e083d22c2_h.jpg) (https://flic.kr/p/2jbQG9W)IMG_8110 (https://flic.kr/p/2jbQG9W) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50004995048_08989f54e4_h.jpg) (https://flic.kr/p/2jbLET3)IMG_8116 (https://flic.kr/p/2jbLET3) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50005779667_487e8dc7aa_h.jpg) (https://flic.kr/p/2jbQG7X)IMG_8118 (https://flic.kr/p/2jbQG7X) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Also these are the carb needle securing screws, one of which is damaged. Is there a reason for this little spot on the top? They all have one so I can't imagine its a coincidence?

(https://live.staticflickr.com/65535/50005779577_38e62cf7f8_h.jpg) (https://flic.kr/p/2jbQG6p)IMG_8120 (https://flic.kr/p/2jbQG6p) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on June 14, 2020, 06:47:01 PM
Its to tell you are jis not phillips or pozi.
Good luck with the insulator clips, them must NOT  be any wider or it will cause air leaks
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 14, 2020, 10:40:46 PM
Its to tell you are jis not phillips or pozi.
Good luck with the insulator clips, them must NOT  be any wider or it will cause air leaks

Well you learn something new every day!

Are the insulator clips the ones which hold the carbs to the rubbers between the manifold and airbox?

Also any ideas or insight on the jetting/needles?
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: K2-K6 on June 15, 2020, 02:14:27 PM
Seems that currently the view is that original Kiehin jets are simply more accurate than alternative replacements. Which is highly desirable for such fine metering these carbs have to do.

If the main jet is just one that has the outside a bit tatty it would be worth filing off the sharp burr and using that with new o-rings, as oddjob indicates, to get a full working set.

The damage hasn't impacted the critical surfaces as far as I can see from your pictures.

Nice work so far,  it'll definitely pay off when running again.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 15, 2020, 06:20:31 PM
Where to start  ;D ;D

98 mains and 38 pilot jets are correct for a 550F.

I presume you've ordered a set of Viton O-Rings for the carbs, they'll need Viton because the new fuel has Ethanol in it and the old style O-Rings really don't like Ethanol. Julie on here sells the kits. She also sells the figure 8 links for the vacuum adjusters.

Whoever put all that black gunk all over the main jet clearly did that because the O-Ring actually holds it in place, as they age they shrink and thus the jet starts to drop out, stupid really but it it what it is, you'll need a new main jet, shame as I just sold a set of 98 mains I'd had for years and years. According to Honda the clip on the needle should be on number 2. However they fail to say from the top or the bottom but I'd imagine it was the top. If so those are correct. Can't remember now what size those screws are holding the needle in place, might be 3mm, might even be 2mm. Have you measured one?

I've used these clips with good results,

https://www.stainlessmiddleton.co.uk/34313-hose-clamps
Extra narrow 31-51mm. Not the cheapest but really nice looking clamps, you want them tight but not too tight.

If your replacing the hoses you'll need Vitrile hosing. Just bought some for my carbs so I'll look what sizes I bought etc and let you know.

How far you go to restoring the carbs is up to you. Doing a really good job involves have some of the parts BZP plated, these include the butterfly and connecting rod etc, all the choke linkages, springs etc. Takes time and a little money and a whole lot of patience and effort but looks really nice after.

Hahaha I do have just a couple of questions...  :-[

Thanks for confirming Ken. I have already got the Viton O-Ring kit from Julie, when you say the figure of eight links are you referring to these bits as pictured below? if so then that would be mega to replace both!

(https://live.staticflickr.com/65535/50005780167_bf2003ab4b_h.jpg) (https://flic.kr/p/2jbQGgz)IMG_8062 (https://flic.kr/p/2jbQGgz) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Just my luck that you've only just sold them! Right that makes a lot of sense, there's clearly been a bit of bodging along the way. They clearly made some efforts at fixing items such as re-tapping some of the float bowl holes... I would agree from what I've seen that they were correctly fitted per the factory settings, which is reassuring. I measured and the screws are M3 - 10mm screws, I'm trying to get stainless replacements for the lot of them from my contact.

Thanks for the heads up, I'll keep it saved for future reference. I actually ordered some black stainless ones which are 30-45mm which I hope will fit and be very subtle and not blingy compared with bright new stainless items. I'll wait and see.

Many thanks on the hose front, I now think the main hose has an internal diameter of 5.5mm and the smaller 3.2mm but not 100%. Shame about all the ethanol that's going into the fuel these days!

I must confess I'm not a huge fan of the whole pimped up zinc factory finish on various metal components. I know its OEM however if I was going all out then I'd just get the lot vapour blasted, I think that comes up amazing. That said, this is very much a functional rebuild rather than looking to build a show bike so I've taken them cosmetically as far as they need to go for me, for now. I just would really like them to operate smoothly and as intended so that the engine operates correctly.

Seems that currently the view is that original Kiehin jets are simply more accurate than alternative replacements. Which is highly desirable for such fine metering these carbs have to do.

If the main jet is just one that has the outside a bit tatty it would be worth filing off the sharp burr and using that with new o-rings, as oddjob indicates, to get a full working set.

The damage hasn't impacted the critical surfaces as far as I can see from your pictures.

Nice work so far,  it'll definitely pay off when running again.

Thanks for the insight, it's a shame you can't get the same quality these days. I've cleaned all of the components in the ultrasonic for 30 mins and in the case of the brass components, polished them up with the dremel so they're smooth, and blasted compressed air through to clear them. I feel they're as good as they can be now.

That's the only one that I noted with visible damage, I may have a go at cleaning it up in that case. I presume the critical parts are the central hole in the jet itself and the O ring mounts to seal the jet in correctly? So I can afford to lose a little bit of material where the damage is?

Thanks I'm certainly keeping my fingers crossed!

For reference I've called around everywhere I can think of today and I cannot find anyone selling 98 main jets to replace it with anyway so it looks like I have very little choice but to try and repair the one I have.   
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on June 15, 2020, 07:31:31 PM
Ken you can get 95's from siriusconic in Canada but you gotta search for them their web search is naff, think i found them under 550
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: K2-K6 on June 15, 2020, 07:35:49 PM
"That's the only one that I noted with visible damage, I may have a go at cleaning it up in that case. I presume the critical parts are the central hole in the jet itself and the O ring mounts to seal the jet in correctly? So I can afford to lose a little bit of material where the damage is? "

Yes as you describe,  the o-ring keeps them in place and prevents any unmetered fuel from bypassing the jet orifice.  The burr area is ordinarily not touching much so plays no real part in their accuracy unless so severely impaired they'd not locate perpendicular to the casting.

If you struggle for any particular stainless bolts,  AHC on the old A30 in Camberley will usually hold stock of most items individually.  You can park in the road adjacent to there as it's restricted out front of shop.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Rob62 on June 16, 2020, 09:33:32 AM
Proper job cornish IPA aldi special......my current tipple of choice  8)
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: sye on June 16, 2020, 12:47:08 PM
Take a look here for #98 main jet:
https://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-carburetor-parts-keihin-cv-secondary-jet-98-026-051.html
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 16, 2020, 06:49:07 PM
Thanks Ken, very helpful as ever.

Julie has saved the day for the second time now  :)

The fuel line sizing seems confusing as ever I already had some 5.5mm and 3.2mm here and the 5.5mm is perfect for the fuel hose from the Petcock lines however the connecting hose between carbs 1-2 and 3-4 is clearly a smaller diameter, the 3.2mm fits but is way too tight and the 5.5mm is too loose. I've ordered some 4mm now as well as it is what the old stuff appears to measure at and I think would be more appropriate. I'm keeping my fingers crossed.

Understandable on the BZP finish, I'm very aware that no meaningful cleaning will be possible as soon as these are reassembled and fitted back up. I'm not to fussed though, at the end of the day, all of my toys are there to be used, not to win show and shine competitions  ;)

Yes as you describe,  the o-ring keeps them in place and prevents any unmetered fuel from bypassing the jet orifice.  The burr area is ordinarily not touching much so plays no real part in their accuracy unless so severely impaired they'd not locate perpendicular to the casting.

If you struggle for any particular stainless bolts,  AHC on the old A30 in Camberley will usually hold stock of most items individually.  You can park in the road adjacent to there as it's restricted out front of shop.

Thanks for confirming, I've had a further inspection this evening and this is the only jet showing damage thankfully. Frustratingly someone really has previously battered it though, however it doesn't look like it will effect how it seats. I think with new seals fitted it should fit back up ok and seal however I'd welcome any further input?

Pictures below showing the worst of it:

(https://live.staticflickr.com/65535/50013397031_d49aee8710_b.jpg) (https://flic.kr/p/2jcvJuP)IMG_8151 (https://flic.kr/p/2jcvJuP) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50012869723_7905d25058_c.jpg) (https://flic.kr/p/2jct2Ki)IMG_8152 (https://flic.kr/p/2jct2Ki) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Thanks for the heads up, that's much appreciated. I've gone for one of these Mega Packs from Mr Megapack so will post up what turns up later this week all being well.

Proper job cornish IPA aldi special......my current tipple of choice  8)

Hahaha its not bad for the sunny weather we've had of late  8) Certainly not a session beer though! 

Take a look here for #98 main jet:
https://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-carburetor-parts-keihin-cv-secondary-jet-98-026-051.html

Thanks, that's much appreciated. I was hoping for a UK supplier though as I want these put back together this weekend all being well. The US seems to have all the good stuff, just like when I'm looking for parts for my 240z  ::)
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 17, 2020, 12:18:53 AM
Ahh my mistake and ignorance showing through, I was referring to the air vent pipes that connect in-between the carbs. I'm assuming that should be 3.5mm pipe then? Typically I have 3.2mm pipe already and will soon have 4mm pipe as well. 

As long as it's not going to have any operational impact then that will have to do for now. I would imagine that ordering a replacement set from the US at a later date to replace all of them so that they are matching would be the solution. It could be that I rejet later with an exhaust change anyway.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: s7paul on June 17, 2020, 07:02:11 PM
I've just bought some hose to replace my old split and age-hardened original engine breather.  Finding that the OEM item is discontinued, I got some of this:

https://www.carbuilder.com/uk/low-pressure-fuel-vent-drain-hose-10mm-id

Fits perfectly, and is a bit more flexible than the original.

Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: motty on June 18, 2020, 08:40:13 AM
By all means use that jet "for now" but I would be purchasing one to have in the spares box ready for the next time the carbs come apart

Sent from my Moto E (4) Plus using Tapatalk

Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: K2-K6 on June 18, 2020, 01:53:17 PM
By all means use that jet "for now" but I would be purchasing one to have in the spares box ready for the next time the carbs come apart

Sent from my Moto E (4) Plus using Tapatalk

I'd like to support the contra view,  in that the jet is really just cosmetically damaged and dressed off with a file will perform as original. The seal and bore being the critical performance elements.

As it's part of the original set ( more of us are holding the view that original brass in good condition is hard to match with replacements) and these running best with accurate fuel metering,  I feel it's advantageous to keep an original.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: motty on June 18, 2020, 06:53:23 PM



I'd like to support the contra view, 
Yes, I seem to be a voice in the wilderness on this particular option. However it doesn't hurt to hear a different viewpoint

Sent from my Moto E (4) Plus using Tapatalk

Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 18, 2020, 09:45:10 PM
Use 3.2mm line for the small inter connecting pipes Woody, little smear of silicon grease/oil on the brass ferrule and they'll slide on easy. They never need to be removed except when the carbs are dismantled and TBH a tight fit is far better than a loose one in this location. I'd advise the same on the new O-rings, I used to fit 1 & 2 and 3 & 4 carb bodies together with the T pieces and the inter connecting tube and fit one pair to the bracket very loosely, insert the spring retention pin between 2 & 3 and then insert the other pair, again very loosely. You could then connect the lifter arms to each carb before tightening the screws up a little. Might be me but I'd fit all the jets etc after getting to this part, the carbs will stand on the tops of the carbs quite well making it easier to work on. I'd put the top covers on last of all.

Check that the 2 screws fitted to the butterfly system are doing their jobs along with the eccentric cam bolt. Instructions in the manual.

Noted with thanks, makes a lot of sense now knowing the function. Certainly lubing the fresh rubber on is no bad thing. Parts supply is certainly slowing me now for sure.

Is it worth getting a tool for measuring the float height? or is is easy enough with a measure?

How are the felt rings fitted to the lifter arms Woody?

They're all good with the exception of this one:

(https://live.staticflickr.com/65535/50019962078_0a670bb062_h.jpg) (https://flic.kr/p/2jd6o4h)IMG_8176 (https://flic.kr/p/2jd6o4h) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Input gratefully welcomed, I feel there's very little that I can do. Again, no idea of its exact purpose.

These bits of rubber are also looking very tired however I've not been able to track down replacements anywhere...

(https://live.staticflickr.com/65535/50020500051_17900d10a9_h.jpg) (https://flic.kr/p/2jd98YF)IMG_8070 2 (https://flic.kr/p/2jd98YF) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Haha you've got to love an opinion, I feel as though there's merit to both arguments. I'm going to reassemble as is and see how I can get it running however realistically I'd love to replace it. If nothing else its unsightly even if unseen. At the end of the day I only really care about it functioning correctly....
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 18, 2020, 11:35:51 PM
I've just starting making some of the felt washers for the carbs Woody, I'll send you 4 to test if your interested, FOC.

I soak mine in silicon oil as it lubricates the lifter arm thus ensuring a smoother throttle action.

Proper float gauge is always a worthwhile investment, they ain't dear.

Have you by any chance got a brake bleeder, one of those that sucks out the fluid from the bleed nipple? Saw a decent video today of one of those being used to test the float valve seat, connect it to the fuel intake and pump the bleeder, gauge goes up indicating vacuum created, this whilst the carb is upside down and bowl off, if the vacuum starts to drop there is a leak, maybe on the seat to valve area or possibly the O-Ring on the valve seat not sealing. If you spray it with WD40 for instance you can actually see the air being sucked down past the O-ring. We all assume that leaks are caused by bad seating or wrong float height but we all seem to ignore the O-ring as a potential cause.

I couldn't possibly say no to that!  8)

I suppose that's the best bet to try and keep it running smoothly!

True, it's amazing how fast all of these '£20' here and there add up though!  :o I believe I'm correct in saying that the correct height is 22mm?

Very interesting, I have got one however I've never been impressed by it. I've never really found a good brake bleeder that I'm really convinced by, I suppose the issue in itself is making a really tight seal for it to test accurately.

It looks like I won't be making the desired progress this weekend while I wait for the rest of the parts to turn up, patience is a virtue I'm told!
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 20, 2020, 12:31:20 PM
Well now you have a use for that bleeder  :D :D You could try sealing off one end of the T piece, connect the brake bleeder to it via a suitable pipe, fit the float valve seat (don't forget O-Ring) and the float valve plus float and pin and then stand on it's head so the float is depressing the pin, then see if you can maintain a vacuum, I suppose like mine it has a gauge on it which increases the more you pump.

If it works maybe you could take a video and show the results so others could copy.

I'll get you 4 new felt rings in the post Woody, let me know how they perform, the problem with them is that they are so fragile, any sideways stress gets them tearing. I'll pre-soak them in Silicon oil as well.

Yep 22mm is right

hahaha I'll see if I can find it, I always hoped it would be a much more useful tool than I ever found it to be. I think finding something suitable to block off the T joint could be entertaining bearing in mind the vacuum that will be created and associated pressure.

You're a legend Ken, I think I'll be deferring the rebuild until next weekend now. I should have your felt rings then and I've just found a rebuild kit with the correct 98 main jet so intend to replace it for peace of mind. I'm going to check the pipe fitment that I have too and see whether I need to order any 3.5mm.

Thanks for confirming the 22mm, I've got a small steel rule so I'm hoping that'll perform the job just fine.

I also had this kit turn up this morning so fingers crossed there will be no more waiting around for any screws!

(https://live.staticflickr.com/65535/50025766472_c335ec5625_h.jpg) (https://flic.kr/p/2jdB8v3)IMG_8187 (https://flic.kr/p/2jdB8v3) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on June 28, 2020, 11:40:26 PM
Well I feel that I should post something up here, there has been lots of progress made albeit the carbs are still sat on my workbench waiting for the last part to come in before reassembly.

(https://live.staticflickr.com/65535/50056078201_1bc520e271_h.jpg) (https://flic.kr/p/2jghu84)IMG_8270 (https://flic.kr/p/2jghu84) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

The front end of the bike has been stripped, I've already refurbished the front brake caliper. There was a some gunk in there and some corrosion so its been through the ultrasonic and given that there was some pitting to the piston that's being replaced. I just need to drop the new piston and seal in now that its been repainted. The brake MC rebuild kit should be in tomorrow to let me crack on with that too. There was a hideous amount of dirt and grime all around the mechanism so its all been cleaned up now. Guess which ones fuel and which one's brake fluid...  ::)

(https://live.staticflickr.com/65535/50056078101_bdea75b181_h.jpg) (https://flic.kr/p/2jghu6k)IMG_8260 (https://flic.kr/p/2jghu6k) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50056324872_1d8377a37b_h.jpg) (https://flic.kr/p/2jgiKs1)IMG_8248 (https://flic.kr/p/2jgiKs1) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50056325642_23f55ab02c_h.jpg) (https://flic.kr/p/2jgiKFh)IMG_8244 (https://flic.kr/p/2jgiKFh) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

As if I needed any more encouragement for my new braided brake lines, these had erm seen better days  :-\

(https://live.staticflickr.com/65535/50056324922_b5f66ac006_h.jpg) (https://flic.kr/p/2jgiKsS)IMG_8230 (https://flic.kr/p/2jgiKsS) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

I also realised that this was never going to be  going in back straight ever again so I'm, waiting on replacements from David Silvers

(https://live.staticflickr.com/65535/50055502323_00a452f4f5_h.jpg) (https://flic.kr/p/2jgewW8)IMG_8211 (https://flic.kr/p/2jgewW8) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

The front forks have been fully stripped and after a battle with the oil seals, they're now free! Much hammering with a pry bar later, after them being extremely stubborn... As you can see the lower threads were looking very sad so I've restored them back to glory and have new stainless hardware to be hidden under copper slip. I'm planning to paint up the lower forks and new seals should be in tomorrow to allow me to rebuild those with fresh oil. The oil looked hideous, it was totally black with deposits in the bottom and smelt horrendous for whatever reason. The forks certainly needed some TLC.

(https://live.staticflickr.com/65535/50056325232_0dbd2ee610_h.jpg) (https://flic.kr/p/2jgiKyd)IMG_8280 (https://flic.kr/p/2jgiKyd) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50055501638_157e463bdd_h.jpg) (https://flic.kr/p/2jgewJj)IMG_8281 (https://flic.kr/p/2jgewJj) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50055501833_7c03459307_h.jpg) (https://flic.kr/p/2jgewMF)IMG_8336 (https://flic.kr/p/2jgewMF) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50055501978_de8c8424ca_h.jpg) (https://flic.kr/p/2jgewQb)IMG_8339 (https://flic.kr/p/2jgewQb) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

I also have a new aftermarket 7 inch headlight and headlight bracket to go on, and am working out my options to install LED indicators to clean up the front end. I know the purists won't like me but I'm looking to modernise the bike in several areas. I will have some work to do on the wiring first though as some of the PO's have made a mess and their standard's are concerning to say the least!

I'm going to have to spend some time with the wire wheels on the front fender to see what comes up however its really seen better days. It's making me feel better about my intentions to potentially take a grinder to it to chop it down and simplify the front end.

(https://live.staticflickr.com/65535/50056325167_f0b22f1adb_h.jpg) (https://flic.kr/p/2jgiKx6)IMG_8272 (https://flic.kr/p/2jgiKx6) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

My new Avon Road Rider Mk2 tyres have also turned up, there was no way the 18 year old tyres were being left so new inner tubes and rim tape are sitting at the ready. I just need to work out whether these are something I can install myself with some tyre irons? I've gone for a 3.25 - 19 for the front and 4 - 18 for the rear which seemed fairly close to stock given the available compound choices.

(https://live.staticflickr.com/65535/50056078451_e50768facb_h.jpg) (https://flic.kr/p/2jghucn)IMG_8301 (https://flic.kr/p/2jghucn) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Equally is there any advice around wheel bearings on these bikes? should I be able to recycle whats there or is it best to just replace?

A guy from the farm I'm working on also kindly lent me a compression tester so I've now done that this weekend with the following results (cold test as the carbs are removed)

Cylinder 1 - 120psi
Cylinder 2 - 115psi
Cylinder 3 - 127psi
Cylinder 4 - 125psi

Noting the low figure on Cylinder two this evening I did a further wet test having dropped in a few drops of oil to see what happened and it jumped up to about 128psi so it looks like I have some wear to the rings on Cylinder two if I'm correct? Anything to be worried about at this stage?

I fully intend to conduct an Italian tune up once I've got the bike back on the road just to try and clear everything up and see how its really running but sadly that's still quite a way off yet...

More to follow soon I hope!   
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on July 01, 2020, 11:41:03 PM
No worries Ken, they've now been received with thanks! I'll be cracking on with those this weekend now I hope. I'll have to wait and see what fun and games now await me.

Thanks for the heads up, I've been remarkably surprised how well the original ones have come up in all honestly, given they're not broken or beyond repairing, I'm happy to just leave them restored and covered in copper grease. In terms of the exhaust, I think I'll let sleeping enemies lie for now. I've got enough to deal with without creating more issues. No doubt I'll tackle them eventually though!

Any input on any of the above points from your experience? 

The good news is that the front forks went back on tonight and I've sorted the mess that was the headlight wiring. Looks of horrible destroyed connectors have been cut out and replaced and I now have a fully functioning 7inch headlight and pilot light so I should be good come the darkness now!   
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Rob62 on July 25, 2020, 11:48:29 AM
Wow missed this thread but the bike in the first photo’s looks fantastic... i always liked the look of the F models even though I actually owned a K3 back in the day... that marshall pipe is in deed a period item and looks to be in amazing condition i hope you decide to keep it but it must be worth a few bob if you dont..?. I had the exact pipe on mine and it did sound nice, not too loud. 8)
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on July 25, 2020, 01:53:59 PM
Well I'm long overdue an update here  :-[

My experience tells me that replacing even for new Oe ones is best done before they get too bad, they tend to snap off flush with the head as that’s where the majority of the rust is and being so close to the head you normally don’t see it until it’s too late.

As you can imagine getting one out when it’s snapped off flush is not easy

Advice has been heeded, I've not got all of the original exhaust studs out and have already received replacement stainless ones from the suggested link. I just  want to run a tap through the threads to clean them up before putting the new stainless ones in. 

Wow missed this thread but the bike in the first photo’s looks fantastic... i always liked the look of the F models even though I actually owned a K3 back in the day... that marshall pipe is in deed a period item and looks to be in amazing condition i hope you decide to keep it but it must be worth a few bob if you dont..?. I had the exact pipe on mine and it did sound nice, not too loud. 8)

Thank you very much, I fear you may be about to be disappointed on a couple of fronts, particularly if you're more of a purist though :-X

The exhaust has actually just been removed, the style/fitment didn't fit in too well with the style of build I was going for. As shame as it did actually sound really good. It's in fantastic condition for its age with the exception of a dent to the underside on the pipe on cylinder two which clearly had an  argument with a kerb at some point during its life... Any ideas on what it may be worth? I'm certainly open to selling it now that I've received a sleeker Delkevic system to replace it.

(https://live.staticflickr.com/65535/50151085766_85402145a1_h.jpg) (https://flic.kr/p/2jpFqyw)IMG_9027 (https://flic.kr/p/2jpFqyw) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151322262_7e655ea313_h.jpg) (https://flic.kr/p/2jpGCS3)IMG_9013 (https://flic.kr/p/2jpGCS3) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151330432_a9132becca_h.jpg) (https://flic.kr/p/2jpGFhU)IMG_9017 (https://flic.kr/p/2jpGFhU) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Over the past few weeks I've now managed to fully rebuild and reinstalled the front forks, at the same time the new aftermarket 7inch headlight has gone on with a CNC'd sleeker mount to remove the big factory sleeves. The electrical system has needed a fair bit of TLC in places with some horrendous work completed by the PO. Knackered connections or wires  twisted together with a bit of electrical tape seem to be a staple, however all being well I've corrected everything with crimped brass bullet connectors.

(https://live.staticflickr.com/65535/50151319682_2e2ade7b96_h.jpg) (https://flic.kr/p/2jpGC6y)IMG_8435 (https://flic.kr/p/2jpGC6y) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151322117_4c7c7e733e_h.jpg) (https://flic.kr/p/2jpGCPx)IMG_8954 (https://flic.kr/p/2jpGCPx) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151319922_e6dd6cb3a1_h.jpg) (https://flic.kr/p/2jpGCaG)IMG_8459 (https://flic.kr/p/2jpGCaG) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50150535803_788a95200a_h.jpg) (https://flic.kr/p/2jpCB5p)IMG_8460 (https://flic.kr/p/2jpCB5p) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

The front disk brake caliper has been stripped and rebuilt with new seals and repainted. There's new HEL braided lines and EBC pads to hopefully  improve the feel of things too. While there I've also stripped and rebuilt the MC so short of bleeding the system they're new, I'm hoping my brakes will be working slightly above their optimum!

(https://live.staticflickr.com/65535/50150535423_2ddedc9d65_h.jpg) (https://flic.kr/p/2jpCAXR)IMG_8422 (https://flic.kr/p/2jpCAXR) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Continuing along the electrical theme I've installed the NOS switch from Ken which looks so much better then the aged US market switch that had been fitted. The problem is that its now made my other switch show its age!

(https://live.staticflickr.com/65535/50151086286_3f9d9a15f0_h.jpg) (https://flic.kr/p/2jpFqHu)IMG_8660 (https://flic.kr/p/2jpFqHu) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50150536278_b6feebd353_h.jpg) (https://flic.kr/p/2jpCBdA)IMG_8675 (https://flic.kr/p/2jpCBdA) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

With the front rim off, I got it stripped down to assess where I was looking at my options for a basic refresh before getting the new tyres fitted. Safe to say I was a little horrified to discover this when I finally got the old  tyre off!   

(https://live.staticflickr.com/65535/50151320252_f6f69edf4e_h.jpg) (https://flic.kr/p/2jpGCgo)IMG_8657 (https://flic.kr/p/2jpGCgo) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151321422_0ae9d55d14_h.jpg) (https://flic.kr/p/2jpGCBy)IMG_8770 (https://flic.kr/p/2jpGCBy) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50150536088_804d0cad4c_h.jpg) (https://flic.kr/p/2jpCBaj)IMG_8602 (https://flic.kr/p/2jpCBaj) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151321292_70db9c1166_h.jpg) (https://flic.kr/p/2jpGCzj)IMG_8765 (https://flic.kr/p/2jpGCzj) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151087481_1843d36a41_h.jpg) (https://flic.kr/p/2jpFr56)IMG_8768 (https://flic.kr/p/2jpFr56) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

I wire wheeled the rim however having looked at all of the rust, looking at a few bent spokes, surface rust on others and shot bearings and retainers, I've decided that none of it was worth risking my life on. I've now sent both rims off for full rebuild. The hubs will soon be clad in new rims with stainless spokes and have all new bearings and tyres to boot. I've keep the stock rim size on the front however decided to bump up the rear to accomodate my 4.0 tyre more comfortably. I wanted to look at bigger rims for more available tyre sizes but really didn't wish to run into fitment  issues down the line so left it  as 1.85 front and 2.15 rear. Fingers crossed that they'll be back in a couple of weeks to refit!
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on July 25, 2020, 02:11:21 PM
This moves me onto my fenders, I'm sure this will meet with distain from certain people. Both had seen much better days with the underside of both appearing to have been totally battered by rust. An aggressive assault with wire wheels was therefore necessary to beat such an enemy back  before converting what metal was left with Dinatrol rust convertor. This proved too much on one section on the rear bumper which actually went all of the way through ::)

The chrome on top of both was on closer inspection pretty pitted and worn out so I didn't feel bad about my decision to paint them. In all honesty I would have been starting again with new if they were staying. The front fender was been slightly chopped and ground down on the front and rear to shorten it and remove the extra supports. I'm hoping this gives me a more modern aesthetic while retaining functionality and stays as the front fork brace. In the end I as pretty happy with the results.

The rear got a very similar treatment however its remained its full size to hopefully keep me drier in the event of foul weather, particularly considering that I plan to tour Europe on it. All of the huge OEM lighting has been removed to make the way for much smaller modern and brighter LED lighting which I prefer for a number of reasons. Efforts have been made to reuse all of the holes where possible and wiring points so my new tailight is nestled perfectly over the rubber wiring grommet.

Some new LED indicators have however been cut neatly into the side of the fender and are almost unnoticeable until turned on. They're incredibly bright and look great I think.

One of my biggest cosmetic victories has been the removal of the hideous old number plate and replacement with a smaller (legal) historic plate. The rear of the bike is now far more to my taste and dare I say it, modernised it hugely. 

(https://live.staticflickr.com/65535/50150535953_21d2a1d386_h.jpg) (https://flic.kr/p/2jpCB7Z)IMG_8548 (https://flic.kr/p/2jpCB7Z) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151320767_27d567f035_h.jpg) (https://flic.kr/p/2jpGCqg)IMG_8690 (https://flic.kr/p/2jpGCqg) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50150536398_acc0476e17_h.jpg) (https://flic.kr/p/2jpCBfE)IMG_8696 (https://flic.kr/p/2jpCBfE) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50150536528_c54583847a_h.jpg) (https://flic.kr/p/2jpCBhU)IMG_8697 (https://flic.kr/p/2jpCBhU) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50150536598_de11498365_h.jpg) (https://flic.kr/p/2jpCBj7)IMG_8689 (https://flic.kr/p/2jpCBj7) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151320867_66b2ed8549_h.jpg) (https://flic.kr/p/2jpGCrZ)IMG_8679 (https://flic.kr/p/2jpGCrZ) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151321027_ebc5a134b2_h.jpg) (https://flic.kr/p/2jpGCuK)IMG_8730 (https://flic.kr/p/2jpGCuK) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151086046_6ae07c0678_h.jpg) (https://flic.kr/p/2jpFqDm)IMG_8588 (https://flic.kr/p/2jpFqDm) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50150537008_9e05ac2ca0_h.jpg) (https://flic.kr/p/2jpCBrb)IMG_8720 (https://flic.kr/p/2jpCBrb) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151321917_0a04749ed8_h.jpg) (https://flic.kr/p/2jpGCL6)IMG_8875 (https://flic.kr/p/2jpGCL6) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151321727_3fa5fc471d_h.jpg) (https://flic.kr/p/2jpGCGP)IMG_8801 (https://flic.kr/p/2jpGCGP) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151087651_05d218ff96_h.jpg) (https://flic.kr/p/2jpFr82)IMG_8867 (https://flic.kr/p/2jpFr82) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on July 25, 2020, 02:37:10 PM
With the old exhaust fully stripped off the cleanup has begun, everything looks very sooted up and I'm not sure whether there is a slight oil leak showing from the cylinder head potentially looking at the below photo?

(https://live.staticflickr.com/65535/50151088226_818db6906a_h.jpg) (https://flic.kr/p/2jpFrhW)IMG_9020 (https://flic.kr/p/2jpFrhW) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50151088421_b11194fb12_h.jpg) (https://flic.kr/p/2jpFrmi)IMG_9025 (https://flic.kr/p/2jpFrmi) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

The studs could have been far worse however they still gave same fight having been painted in place for some extra resistance. I'm grateful that they all came out in one piece before it was too late. I'm keeping fingers crossed that the new stainless ones with some copper slip will avoid any headaches down the line.

(https://live.staticflickr.com/65535/50151088326_c7fed32138_h.jpg) (https://flic.kr/p/2jpFrjE)IMG_9023 (https://flic.kr/p/2jpFrjE) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

I'll certainly be doing a little clean up before the new copper crush gaskets ands exhaust gets bolted up.

In other news, I was very aware how basic the rear suspension felt on my original ride home several months ago now. Clearly something was needing to be done. Being a bit of a tart I wanted something more adjustable given that I have various different uses planed and have therefore picked up a set of TEC's fully adjustable rear shocks. Time will tell whether they are any good or not but they certainly look the part.

(https://live.staticflickr.com/65535/50150538018_963ad3e0cc_h.jpg) (https://flic.kr/p/2jpCBJA)IMG_8928 (https://flic.kr/p/2jpCBJA) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Having now cleaned up the back end of the bike in most other respects and being conscious of how uncomfortable old bike seats can be I've decided to send off my seat for some TLC. I wanted to retain the originality of the mechanism and didn't wish to cut or weld the frame in the  event that someone wishes to revert the bike back to standard one day. That said the seat will be being spruced up to give it some more character, lower the profile and improve upon the comfort significantly. I'm very excited to see howe this turns out, but have total faith in the company that its been  sent  to having seen their other work.

The carbs were  fully reassembled a couple of weeks ago. Id be lying if I said that a lot of patience was not involved. It was rather painstaking getting it all just so, bench syncing the carbs and also resetting the float heights to get it all just so. Despite this I still managed to pinch the O ring seals on the fuel pipe for carbs 3 and 4 causing a fuel leak having fully rebuilt the carbs and got them on the bike. Thankfully those have now been replaced with a huge shoutout to Julie of here!

I also decided to replace the damaged main jet on carb one for  peace of mind so there should be no dramas there. It was incredible what a difference it made to the bike on first  startup even with no proper vacum sync or balance. I'm pleased to report that it is sounding so much healthier so I'm feeling a lot better. Exhaust to go on next to finish that area up.

This is where the bike currently stands, its felt like one step forward, two backwards throughout and I've gone so over budget and more carried away then anticipated however I'm hoping it'll be something that I'm very proud of and really enjoy around Europe come September.

I've probably missed a lot however that gives you the headline pieces I'm sure and I've already written too much  :-X

(https://live.staticflickr.com/65535/50150538173_0ea27cf9d2_h.jpg) (https://flic.kr/p/2jpCBMg)IMG_8940 (https://flic.kr/p/2jpCBMg) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Rob62 on July 25, 2020, 06:49:40 PM
Don't worry I’m nor a purist, each to his own is more my view.... Looks like you have plenty to keep you busy there... shame about the Marshall pipe, I’ve no idea of its value but it must be very rare to find one in that condition, it would suit anybody who is trying to build a special but in the 80’s style.... I haven’t seen one fitted to a classic honda for decades and I’ve certainly looked at plenty in the last few years...
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on July 27, 2020, 09:56:41 PM
Don't worry I’m nor a purist, each to his own is more my view.... Looks like you have plenty to keep you busy there... shame about the Marshall pipe, I’ve no idea of its value but it must be very rare to find one in that condition, it would suit anybody who is trying to build a special but in the 80’s style.... I haven’t seen one fitted to a classic honda for decades and I’ve certainly looked at plenty in the last few years...

Refreshing to hear, I know people have strong opinions in the vintage community. I guess my plans are somewhat odd in that I'm not going OEM or cafe/brat etc anyway. It seems never ending sadly!

Thanks for the info, I hadn't appreciated it was a period and unique piece. The dent to the pipe is certainly a great shame and something I hadn't noticed at the time. I'm hoping to find a new owner who will appreciate it and put it to good use, soon to be up for grabs anyway. The delkevic that I've picked up certainly seems the business for me at least.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Safo on July 27, 2020, 11:09:33 PM
Nice finish on the forks and mudguards, looks great, hope all goes well
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on July 28, 2020, 07:11:15 AM
Your too far from me to buy the exhaust im affraid
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Rob62 on July 28, 2020, 10:14:03 AM
Here is my delkevic 😎 they are awesome and great value.
(https://i.postimg.cc/HLcQjvXr/8-D301086-BEC3-494-E-977-F-3319-AB74-DF5-A.jpg) (https://postimg.cc/8FGF0HyG)
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Rob62 on July 28, 2020, 05:32:20 PM
And the chain !!  >:( >:(

 ;D
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Rob62 on July 28, 2020, 09:46:42 PM
The bastards.....  ;D
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: heli_madken on July 31, 2020, 05:26:06 PM
We have your parts here -
[attach=1]

My organisation - SPECRE SPecial Executive Counter Restoration of Early Hondas has taken them

So Mr. Rob62 to maintain the full originality of your pathetic motorcycle, you must pay me -

$1,000,000

You have just 24hrs before I hand them to Wolfgang for complete destruction

[attach=2]

I warn you Mr. Rob62 we expect your parts to DIE if you do not pay
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Nurse Julie on July 31, 2020, 05:44:26 PM
We have your parts here -
(Attachment Link)

My organisation - SPECRE SPecial Executive Counter Restoration of Early Hondas has taken them

So Mr. Rob62 to maintain the full originality of your pathetic motorcycle, you must pay me -

$1,000,000

You have just 24hrs before I hand them to Wolfgang for complete destruction

(Attachment Link)

I warn you Mr. Rob62 we expect your parts to DIE if you do not pay
🤣🤣🤣🤣🤣 That made me laugh.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on July 31, 2020, 07:44:51 PM
Cute puddy tat!!!
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on July 31, 2020, 10:06:40 PM
Nice finish on the forks and mudguards, looks great, hope all goes well

Thanks man, much appreciated  :D

Your too far from me to buy the exhaust im affraid

If you're interested then I'm more than happy to bubble wrap and post it, if not then no worries, I'll advertise when I find some time.

Here is my delkevic 😎 they are awesome and great value.
(https://i.postimg.cc/HLcQjvXr/8-D301086-BEC3-494-E-977-F-3319-AB74-DF5-A.jpg) (https://postimg.cc/8FGF0HyG)

They do look mega I must say! Nice bike you've got yourself there, CB750?
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Rob62 on July 31, 2020, 10:21:59 PM
Thanks woody!
And for the stolen parts, they have mysteriously re appeared 👍👍
(https://i.postimg.cc/G2tqKSwB/E80-D1740-CC28-4-D06-A608-5448227-E59-C0.jpg) (https://postimg.cc/FdtyspKm)
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on August 01, 2020, 02:40:05 PM
It wasnt me it was Julie(not a referance to our wonderful nurse but to a silly movie) EDIT Rocketman movie
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Zoltan on October 02, 2020, 01:12:46 PM
OK, it's in 550F1 trim but you say it's a 1978 bike?

I bought an F2 SuperSport in blue metallic on 2nd August 1977 and still have it. It's in standard original trim, not repainted etc. Photo taken 2 weeks ago for you to compare.  The seat is also now back to standard.

Cheers, Dick
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on October 16, 2020, 04:59:59 PM
OK, it's in 550F1 trim but you say it's a 1978 bike?

I bought an F2 SuperSport in blue metallic on 2nd August 1977 and still have it. It's in standard original trim, not repainted etc. Photo taken 2 weeks ago for you to compare.  The seat is also now back to standard.

Cheers, Dick

Sorry for the slow reply, this has been on total hold while I've been riding across Europe for the last 30 days. 9 countries and 5000km so not bad going in the current environment! I picked up a Honda CB500X for the trip which was absolutely mega, super reliable and have already agreed its sale today.

That is correct on both counts, I can't quite understand it myself. It definitely looks to be an F1 based on my limited knowledge and other more experienced members input however it's also definitely registered as a 1978 bike so I have no idea...

It looks like you've got yourself a really tidy bike there!

Fingers crossed more progress is going to be made imminently, having returned to the UK I've finally picked my wheels back up fresh from a total rebuild. I need to give a huge shoutout to Trigger on here who rather generously saved my rebuild. It turned out that my rear drum brake liner was totally buggered, cracked in five places and had a hole in it. It was in fact so bad that it had to be scraped, thankfully though Graham sorted me with a replacement and turned it around incredibly quickly.

I have to say the wheels do look the dogs bollocks in my opinion having been finished in satin black with stainless spokes, photos to follow soon as I start piecing the bike back together. I'm keeping fingers crossed that I've now got what I need to get it all back together and fingers crossed get back on the road just in time for winter!

Tomorrow I'll also be picking up my seat which has been totally customised and re-upholstered, not one for the purists however from the photo I've been shown I think it looks mega and am looking forward to getting it fitted back up to the bike. More progress to follow shortly I hope, I just need to remember how everything goes back together now  :o

(https://live.staticflickr.com/65535/50493969903_e8fbd02782_h.jpg) (https://flic.kr/p/2jVYN4Z)IMG_1120 (https://flic.kr/p/2jVYN4Z) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: gbjeppm on October 16, 2020, 06:56:34 PM
Mark

Looks like you are doing a cracking job, and I will watch with interest.

I am not far from you near Epsom, and have just started a thread on my CB550k restoration.

Could you let me know who did your seat, that looks great.

Cheers
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on October 17, 2020, 03:01:05 PM
Mark

Looks like you are doing a cracking job, and I will watch with interest.

I am not far from you near Epsom, and have just started a thread on my CB550k restoration.

Could you let me know who did your seat, that looks great.

Cheers

Thanks Matt, hopefully its about to get more exciting as it really comes together and reaches the open road again!

What a small world, I used to go to school in Leatherhead and play rugby against Epsom so know the area well. I'll have to take a look at your build however if you ever fancy kicking tyres and saying hi then don't be a stranger. Maybe I can swing by on the bike once I'm back on the road if you fancy it and subject to all the new rules etc?  :-X

The seat was done by these guys, their work seems to be very impressive. Have a word with Matt, he's a really nice bloke and into classic cars too. I could have gone far more sculpted and bespoke shape wise however I didn't wish to cut the frame at this stage and liked the idea of retaining the factory lock and mechanism for access. Fingers crossed it looks as good once its been fitted back up!

https://www.herbertellisonupholstery.co.uk/upholstery-services/motorbike-seat-upholstery/

Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: gbjeppm on October 18, 2020, 11:14:53 AM
No problem to swing by, will be good to exchange notes, just send me a PM.

Thanks for the info on the seat,
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on October 29, 2020, 07:21:59 PM
No problem to swing by, will be good to exchange notes, just send me a PM.

Thanks for the info on the seat,

Sounds good, hopefully it won't be too much longer and I'll be able to road test so I'll let you know.

In other news I have made the first bit of progress in a long time today. I've now reassembled and fitted the front wheel to the bike and what it difference it has made phycologically! That said it does appear to be out of alignment with the front fender, any ideas from anyone?

(https://live.staticflickr.com/65535/50545022411_6aef43f617_k.jpg) (https://flic.kr/p/2k1uscD)IMG_1852 (https://flic.kr/p/2k1uscD) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

I've also (hopefully for the last time) refitted the carbs up, refitted the airbox, and fitted the reupholstered seat.

A missing O ring seal has held me back from getting the bike completely back down on its new shoes however it's really nice to see the new aesthetic coming together. I know it won't be everyones cup of tea but I'm really liking its stealthy look having lost a lot of the chrome and done some modernisation.

Looks like the remaining short list is to: (subject to a million other headaches  :-X)

- Rebuild Rear Wheel
- Fit the new chain
- Bleed/adjust Brakes
- Change Oil
- Fit up the new exhaust

(https://live.staticflickr.com/65535/50544292213_3648f27431_k.jpg) (https://flic.kr/p/2k1qH92)IMG_1828 (https://flic.kr/p/2k1qH92) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50545162692_438ff3549d_k.jpg) (https://flic.kr/p/2k1vaUh)IMG_1849 (https://flic.kr/p/2k1vaUh) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50545022446_df19e6db5f_k.jpg) (https://flic.kr/p/2k1usdf)IMG_1857 (https://flic.kr/p/2k1usdf) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Nurse Julie on October 29, 2020, 07:44:52 PM
It looks like the wheel is in the correct place but the guard is sitting to one side. You have probably just fitted the guard  fixing point on the wrong side. Post a pic sometime.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on October 29, 2020, 10:51:14 PM
It looks like the wheel is in the correct place but the guard is sitting to one side. You have probably just fitted the guard  fixing point on the wrong side. Post a pic sometime.

Thanks Julie, that could well stack up. I'll have to take a look again next time I'm home and take some photos or see if I can work it out!
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Lobo on October 30, 2020, 09:34:25 PM
I don’t know the CB550...

But, there seems to be excess thread on the Caliper Adjusting screw leading me to wonder whether the axle and various spacers are orientated correctly.

Recently after servicing the front bearings & cleaning my 400F I was ‘shocked’ at the minimal disc - fork tube clearance, I then noted excess caliper adjusting thread and thought, ‘eh up?’ 
Embarrassingly I’d fitted the axle wrong way around. Doh.

Pic of the CB400F... MAY NOT reflect the 550. (& ignore my personalisations)
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on November 08, 2020, 09:58:43 PM
I don’t know the CB550...

But, there seems to be excess thread on the Caliper Adjusting screw leading me to wonder whether the axle and various spacers are orientated correctly.

Recently after servicing the front bearings & cleaning my 400F I was ‘shocked’ at the minimal disc - fork tube clearance, I then noted excess caliper adjusting thread and thought, ‘eh up?’ 
Embarrassingly I’d fitted the axle wrong way around. Doh.

Pic of the CB400F... MAY NOT reflect the 550. (& ignore my personalisations)

Thanks for the suggestion, that was more a case of me messing around with the calliper adjusting screw to try and work out the fitment. The wheel was rebuilt by a 'professional wheel builder' however you never really know...

I looked again the other evening and It appears that I had managed to get the brake calliper mount incorrectly positioned so that it wasn't mounting onto the fender support but instead directly onto the forks. I've since swapped these around and it looks to be much better aligned thankfully!

There's been a lot of progress this week however the finishing line has still managed to evade me.

The rear wheel has now been rebuilt and fitted up with Julie kindly supplying me with the missing seal. This has meant that I could fit up a new chain, having previously picked up an X-ring chain I ultimately decided against its fitment due to concerns over its size so instead ordered a more standard chain from David Silvers.

Having measured the pin widths on both chains I wasn't shocked to find out why the X-ring type chains can start eating away at your engine casing. The new standard chain measured 21.52mm vs the 23.58mm of the X-ring variant! Equally the split pin connection was a lot less hassle...

Refurbed chain guard fitted up, chain adjusted to spec and rear brakes adjusted and progress was being made. Sprocket casings fitted back up and wiring tucked away too.

On the cosmetic front I was very aware of the height of the newly fitted fly screen which left a large gap between the headlight and looked somewhat ridiculous so this has been chopped down, drilled and refinished to fit more in with the aesthetic.

With the bike now off its bricks and fully balanced on its centre stand again, I could finally refurbish the oil filter housing and fill her up with fresh oil so that she's now been fully serviced.

Next up and my freshly wrapped Delkevic exhaust could be bolted up, having followed the instructions I have somehow managed to hit somewhat of an inconvenient hurdle with the rear silencer/muffler not being able to be fitted as the supporting bracket does not align with the rear footpeg mount as intended. I have therefore been left with a straight pipe setup while I try and work this one out, a message to Delkevic surely however if anyone can offer any wisdom and experience with this set then it would be appreciated.

I'm conscious that I really need to at least get the centre stand rubber stop fitted up if nothing else to prevent any interference with the chain.

Time for the moment of truth and after all of my hard work its time for the first start up in months, the battery hasn’t died which is a bonus. Fuel on, choke applied and ignition button firmly pressed with a twist of the throttle for good measure. Thankfully the musical symphony of four cylinders kicking into life responded, holding it on the throttle while adjusting the choke and idle screw and before you know it she’s ticking over happily at 1200rpm. It’s by far the best the bike has run since I picked it up and what’s more there’s no fuel leaking this time. Not quite sure the neighbours were quite as thrilled with the straight pipe as I was…

One last task and well nothing quite goes to plan, having expected to easily bleed the front brakes to get the bike roadworthy I have been stopped dead in my tracks. Having opened the bleed nipple, put brake fluid in the reservoir and pumped the brake lever the result was totally disappointing. A few tiny bubbles popped up however nothing was going through the system. The brake lever also has very little in the way of resistance, I'm therefore beginning to wonder whether my master cylinder rebuild has gone pear shaped....

On top of this with the brake caliper bolts correctly torqued the front brakes are locked solid and the front wheel therefore seized. In order to get me from the garden into the freshly emptied garage at the front of the house I’ve had to loosen off the brake calliper to allow the wheels to rotate freely.

Any suggestion on trouble shooting would be much appreciated? I’m assuming that the calliper will be totally fine as it was a very straight forward rebuild, the junction with the brake sensor equally was only cleaned and reassembled so I’m looking to blame the master as I had a total battle rebuilding it and now the lever offers little in the way of resistance…

Equally now that its off its centre stand, I really need to get it off to fully refurb and refinish it as its certainly looking very shabby next to the rest of the bike and probably long over due some TLC.

On a more positive note, here’s some photos of where it’s got too. Its totally transformed since May and for the first time in months is rolling on its new shoes and finally getting close to its finished look. Safe to say that I’m eagerly anticipating the test ride in due course!

(https://live.staticflickr.com/65535/50580445373_c2287eedbc_k.jpg) (https://flic.kr/p/2k4C1dn)A7839887-3C4C-4119-B7E8-C49E48A5B6AC (https://flic.kr/p/2k4C1dn) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Problem Identified!
(https://live.staticflickr.com/65535/50581176751_e81e8119f7_k.jpg) (https://flic.kr/p/2k4FKCk)IMG_1960 (https://flic.kr/p/2k4FKCk) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50581303412_050bb984ae_k.jpg) (https://flic.kr/p/2k4Gph9)IMG_1957 (https://flic.kr/p/2k4Gph9) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50581176691_a169ab296d_k.jpg) (https://flic.kr/p/2k4FKBi)IMG_2015 (https://flic.kr/p/2k4FKBi) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50581176611_b212d3aff5_k.jpg) (https://flic.kr/p/2k4FKzV)IMG_2019 (https://flic.kr/p/2k4FKzV) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50581176451_50e7fdb3ef_k.jpg) (https://flic.kr/p/2k4FKxa)IMG_2033 (https://flic.kr/p/2k4FKxa) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50580445813_d3120fab20_k.jpg) (https://flic.kr/p/2k4C1kX)IMG_2059 (https://flic.kr/p/2k4C1kX) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Spot the issue here!  ???

(https://live.staticflickr.com/65535/50581176306_440a8cfff1_k.jpg) (https://flic.kr/p/2k4FKuE)IMG_2062 (https://flic.kr/p/2k4FKuE) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Front end all tidied up
(https://live.staticflickr.com/65535/50581302857_dd1624eed6_k.jpg) (https://flic.kr/p/2k4Gp7z)IMG_2072 (https://flic.kr/p/2k4Gp7z) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50581176006_ef8573b15f_k.jpg) (https://flic.kr/p/2k4FKpu)IMG_2095 (https://flic.kr/p/2k4FKpu) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50580444763_84abd84dfb_k.jpg) (https://flic.kr/p/2k4C12R)IMG_2096 (https://flic.kr/p/2k4C12R) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50580445563_7d35a16dea_k.jpg) (https://flic.kr/p/2k4C1gD)IMG_2088 (https://flic.kr/p/2k4C1gD) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50580445488_af92e4b4c6_k.jpg) (https://flic.kr/p/2k4C1fm)IMG_2093 (https://flic.kr/p/2k4C1fm) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on November 08, 2020, 10:07:22 PM
A quick video to show how its currently running, not the best video however there will be a better one to follow in due course once I've got the braking issues ironed out and the bike roadworthy again.

https://www.youtube.com/watch?v=bFP0lmeAOu4&feature=youtu.be

Compared the the first video I posted earlier this year where it was sounding very rattly, I'm very pleased with what I've achieved for a first build.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Phteix on November 09, 2020, 06:25:34 PM
Nice work. It's looking awesome!

Is this the original seat bowl? Did you cut the frame for that?

Cheers!
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on November 09, 2020, 09:36:34 PM
Remove the caliper adjusting screw and see if the brake binds then.

Exhaust, try removing the springs, fitting the end can and then refitting the springs, they could be pulling the Y section too far onto the downpipes and thus pulling the end can forward.

I will give it a go, what's the science of how the adjustment screw should be set?

I'm also going to disconnect the MC from the brake sensor terminal and see if I can get fluid to pump through to there to ascertain whether or not the MC is the guilty party or not.

Good argument well presented, I may be unfairly over estimating how snugly everything should fit in. I was very keen not to have leaks from the collector from past experience with exhausts. I'd like to think it should be fairly good fitment given delkevics reputation and how many people have them fitted. I'll also give that a go...

Nice work. It's looking awesome!

Is this the original seat bowl? Did you cut the frame for that?

Cheers!

Thank you for the words of encouragement  8)

It is the original seat bowl which has just had the foam chopped around and been re-profiled a bit more to my taste. I didn't wish to cut the frame of the bike and I also wanted to retain the OEM lock and hinged seat for storage and access. It's still not small but a lot neater than OEM for me.

Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: hairygit on November 10, 2020, 07:06:26 AM
Going off memory on the adjustment screw, you set it by screwing it out until the back pad touches the disc, then slacken it off until there’s a 3mm gap, I used to just slacken it until it stopped dragging on the disc
Apart from the fact the gap should be 6 thou or whatever the metric equivalent is!

Sent from my POT-LX1 using Tapatalk

Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: McCabe-Thiele (Ted) on November 10, 2020, 08:30:42 AM
Just been through this post - I like what you have done to the bike it looks really cool a nice mix of modern & classic DNA- the taped manifolds is this to help with heat dissipation? Nice sound on the video.

Lastly I like the B&W plates but as an ex-copper can't see why you think they are legal unless you motor was first registered before January 1973.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on November 10, 2020, 08:39:34 AM
They have changed the rules, anything in "Historic" tax class may use black
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: McCabe-Thiele (Ted) on November 10, 2020, 09:08:22 AM
They have changed the rules, anything in "Historic" tax class may use black
Pleased to hear that traffic was ever my forte plus I've been retired from fuzz for 17 plus years.

I will be ordering a rear B&W rear plate - does it also mean I could mount a knife blade front plate - I always liked the look.
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Bryanj on November 10, 2020, 03:34:05 PM
I dont think they were ever banned, just removed to save pedestrians
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on November 11, 2020, 04:32:09 PM
Thank you for the input regarding the brake setup, duly noted and I'll put it into practice in due course. Having got back home and looked at the bike again I've confirmed that there's must be an issue with how I've rebuilt the MC. With it filled with fluid and the lines being fully disconnected from the brake calliper it doesn't wish to push any fluid through it and the handle provides no resistance.

To confirm and as a short term fix I've ordered a replacement MC and will swap it out to confirm and see if I can't get the front brake fully operational.

Just been through this post - I like what you have done to the bike it looks really cool a nice mix of modern & classic DNA- the taped manifolds is this to help with heat dissipation? Nice sound on the video.

Lastly I like the B&W plates but as an ex-copper can't see why you think they are legal unless you motor was first registered before January 1973.

Thank you very much, its really nice to hear this as its always my goal whenever I rebuild classic machinery  ;D In theory it should help with the heat, however I'll be honest, I've always just loved the aesthetic and really didn't want to have chromed/stainless pipes that scream steal your attention. As you'll have seen I have tried to really tone down the 70's chromed look. I quite like the slightly more subdued modern/retro aesthetic. I'll unusually confess that like this it is a bit too loud though...

As has been mentioned its now perfectly legal being historic vehicle class 8) I've gone for the smallest legal plate and font sizes so that its not an eyesore bolted on like the OEM setup, its basically the same width as the rear mudguard. It certainly helps with the look imo.

In other news I'm still battling with the exhaust fitment, so much for bolt on parts! With everything loosened back off I can get the silencer and collector connected and tensioned up however it feels somewhat stressed and they want to be at different angles to each other.

Not withstanding this, the rear centre stand rubber stop which comes with the exhaust hanger is situated too far rearwards and therefore does not stop it as intended. Having spent a few hours messing with it, something doesn't add up. I've contacted Delkevic however I'm now wondering whether I've been supplied with the wrong securing bracket? and/or the collector is a dodgy one and not been formed correctly.

While I've contacted Delkevic to request assistance however I'd be grateful of anyone else's experience with this system? I presume the rear footpeg mounting hole on the frame didn't alter between the years and revisions of the 550?

Some more photos for context:

Exhaust fully connected and fitted, however slightly stressed due to the stretch and exhaust header pipes now much further outside of the collector pipe:
(https://live.staticflickr.com/65535/50589869193_4a5435c47d_k.jpg) (https://flic.kr/p/2k5siA2)IMG_2147 (https://flic.kr/p/2k5siA2) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50589869098_339dff9c53_k.jpg) (https://flic.kr/p/2k5siyo)IMG_2153 (https://flic.kr/p/2k5siyo) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

(https://live.staticflickr.com/65535/50590610096_a337a46cc3_k.jpg) (https://flic.kr/p/2k5w6Qd)IMG_2148 (https://flic.kr/p/2k5w6Qd) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

Exhaust hanger fitment:
(https://live.staticflickr.com/65535/50589868993_28fafe87eb_k.jpg) (https://flic.kr/p/2k5siwz)IMG_2155 (https://flic.kr/p/2k5siwz) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr

You can see the slight misalignment of the collector pipe and silencer here, as you can imagine this will get worse as the silencer is fitted due to its fixed hanger point meaning it has to turn rather than slide as would be ideal:
(https://live.staticflickr.com/65535/50590609841_cc86bd6fc4_k.jpg) (https://flic.kr/p/2k5w6KP)IMG_2156 (https://flic.kr/p/2k5w6KP) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: robvangulik on November 11, 2020, 09:50:00 PM
Shouldn't that main stand stop be fitted on the forward hanger bolt?
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on November 11, 2020, 10:24:52 PM
Shouldn't that main stand stop be fitted on the forward hanger bolt?

Not according to the fitting guide, its in the correct location. Not withstanding that it won't work as if you spin it around then the 45 degree piece which extends off with the rubber stop wouldn't mate against the flat surface on the exhaust silencer if that makes sense.

I had the same thought as that's clearly where it wants to be positioned to do its intended job...
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: robvangulik on November 11, 2020, 10:29:53 PM
Quote
I had the same thought as that's clearly where it wants to be positioned to do its intended job...
And at the same time a bit out of sight!
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: woody928 on November 15, 2020, 03:51:31 PM
Well nearly six months later I'm back on the road again  8)

Having ordered a new MC I was reading another thread on here and came across BryanJ's advice regarding bleeding freshly built MC's before connecting them up to the brake lines. Some messing later and having hand bled it with all of the lines disconnected, suddenly my rebuilt MC was in business. Some time later trying to expel all of the air from the lines and the system had pressure. Strangely though everything was still binding though so having pulled the calliper apart it turns out that my brake pad had managed to wedge itself at an angle meaning that it was totally seized. Having free'd it and realigned it everything was operating just like Honda intended again. Last job was to leave the brake level cable tied on overnight to help get some feel into the lever and I was back in business today following a few tweaks using the adjustor screw.

The exhaust has now also been fully fitted up, having tweaked the collector position it was possible to get the exhaust sealed up sufficiently to perform as expected. The only real disappointment is that the centre stand stop is sat a good couple of inches too far back to do anything useful.

I've therefore slid it forward a bolt hole so that it is only secured in place with one bolt rather than two, leaving one mounting location literally flapping in the breeze. That said it now performs its intended task and the centre stand clears the chain. Still waiting to hear from Delkevic in the meantime...

There's still a few minor tasks to perform however having doused the bike in ACF50 and lubed the chain it was time to hit the road, taking it steady to see how everything is bedding in and initial signs are really encouraging. The brakes are about effective as you'd expect however a significant improvement over when I picked the bike up, the rear locks easily enough if you desire. The engine is performing a million times better and really happy to pull all the way up the revs now, its literally like a different bike now. Poor weather sent me home however I'll be doing some more road testing as soon as the weather allows. The battery is also happily charging again having repaired the wiring from the alternator.

All that said I think the rear suspension needs some time to bed in a little, and I'm trying to be very careful on my spanking new skinny tyres particularly on damp road surfaces.

When time allows I'd like to remove the centre stand to refurb it as its looking pretty rough, I want to check over some wiring to my taillight and get my phone charger wired into the ignition (thinking to use the wiring to the ignition coils) when time allows for those longer summer days. It appears that the tasks are never ending...

(https://live.staticflickr.com/65535/50605580222_4e19c463e2_k.jpg) (https://flic.kr/p/2k6QPVQ)IMG_2211 (https://flic.kr/p/2k6QPVQ) by Mark Woodrow (https://www.flickr.com/photos/148965131@N05/), on Flickr
Title: Re: 1978 Honda CB550 Supersport - My first retro bike rolling restoration!
Post by: Nurse Julie on November 15, 2020, 04:00:16 PM
Well done Mark.
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