Honda-SOHC
SOHC.co.uk Forums => CB500/550 => Topic started by: Sherlock on July 31, 2012, 07:40:28 PM
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Hi all, I've recently been using the US site, thanks to Ewan I've been directed here, which is a little more closer to home.
I recently bought a CB550 1977 Suoersport F2, a barn fine which is in a bit of a state. However, my objective is to buikd a cafe racer, stripping the bike down and rebuilding from the ground up. I have an endless list of tasks to complete, albeit without a deadline as such.
http://acaferacerisborn.wordpress.com/gallery/#jp-carousel-210
The bike is currently stripped, engine remains in the frame (due to 2 seized lower frame bolts)
Lots to be done to include:
The engine Will be stripped
Frame will be blasted and powder coated
Engine soda blasted and painted
Front end refurb, hub, spokes, rim, caliper, forks, seals etc
Rear end rebuild, hub, spokes, rim, brakes, bearings etc
Rewire
New hoses
New clutch plates
New chain and sprockets
New tyres
New bearings / bushes all round
Carbs stripped, cleaned, polished and parts replaced - cone filters
New clocks/gauges
Respray side panels, tank and cafe seat unit (silver)
New exhaust (downpipes/end can muffler)
Rear sets
Cafe seat
The list goes on...
Some people have asked why I'm not restoring it back to its original showroom condition, well, personally, I have no emotional, historical or sentimental connection with this bike, so with respect, it means nothing to me other than a heap of rust that would make a suitable donor for a cafe racer.
I've always admired cafe racers and love the style of this bike, I was told a CB550 would make a good project bike.
In hindsight it could've done with being in better condition (everything is seized on the damn thing) but then it's all good fun and a challenge to say the last.
Moving forward, I've stripped the bike down to the frame, the forks have been stripped, new seals, oil and a polish. The carbs are half way through being, stripped, cleaned, replacement parts and polished.
The front end is being stripped, I managed to separate the hub from the disc, which seemed to be fused together, it took me about 2 hours.
So that's where I am am at the moment, the engine is being worked on also, rocker and head off so far, bearing in mind it's taking me 5x longer due to everything being seized!! I love a challenge me!!
For more info, pics etc, go to http://www.acaferacerisborn.wordpress.com
I will of course do my best to duplicate the posts here for anyone wanting to follow. I use an iPad a lot which unfortunately and irritatingly doesn't work great when adding photos etc. I will have to dig the laptop out. Does anyone know if this site is on Tapatalk? I know the US version is.
Hope to get to know some of you and obtain valuable advice, experience, tips and tricks :-)
Cheers
Chris
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Chris, I have been trying to install Tapatalk for a week now. I use it on other SMF forums that I manage and I use it myself. If only I could get the bloody server to accept that the access privileges are what my FTP client says they are...
Have you considered installing WP-Touch on your blog. It's good for mobiles but you really need the -Pro version (at a cost) for the special iPad templates. Actually, can you install plug-ins on Wordpress.com? I've always hosted my own.
You can see WP-Touch in action on www.tvam.org - a site that I designed and run for the Thames Vale Advanced Motorcyclists.
Steve
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Yay Tapatalk on iPhone. :-)
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Good luck with your build, i did one last year , you might find some help from my build thread here
http://www.therevcounter.com/uk-motorbike-forum/68285-my-cb550-cafe-racer-build.html
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I'd read your thread as well as a few others, so it's partly your fault I'm in this mess! ;-) lol
Seriously though, great job and a real inspiration.
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Thought I'd add a few pics...
The bike when it arrived...
(http://img.tapatalk.com/516df8df-307d-10a1.jpg)
The concept is based on this...
(http://img.tapatalk.com/516df8df-30a9-4e6b.jpg)
Random...
(http://img.tapatalk.com/516df8df-30cc-22d0.jpg)
(http://img.tapatalk.com/516df8df-30dc-4941.jpg)
(http://img.tapatalk.com/516df8df-30f1-7bd0.jpg)
My Yamaha XJR 1300 SP '99 in the background.
(http://img.tapatalk.com/516df8df-3103-9ca8.jpg)
(http://img.tapatalk.com/516df8df-312f-419f.jpg)
(http://img.tapatalk.com/516df8df-3148-a555.jpg)
(http://img.tapatalk.com/516df8df-315c-d268.jpg)
Almost every bolt is seized...
(http://img.tapatalk.com/516df8df-316e-d46c.jpg)
(http://img.tapatalk.com/516df8df-3189-a8cc.jpg)
Before and after cleaning carbs...
(http://img.tapatalk.com/516df8df-3199-d3aa.jpg)
Seized caliper, used a grease nipple and grease gun to get it out :-)
(http://img.tapatalk.com/516df8df-31c8-deba.jpg)
Rocker cover and breather off, can't see much wear here :-)
(http://img.tapatalk.com/516df8df-31f7-517a.jpg)
Head off, still looking good for 35yrs old.
(http://img.tapatalk.com/516df8df-3226-a230.jpg)
(http://img.tapatalk.com/516df8df-324f-e464.jpg)
I slipped a pic of my beast in !! (http://img.tapatalk.com/516df8df-3262-f019.jpg)
Fork strip down...
(http://img.tapatalk.com/516df8df-3297-7a31.jpg)
Before and after forks...
(http://img.tapatalk.com/516df8df-32ac-627a.jpg)
Yuk!!!
(http://img.tapatalk.com/516df8df-32d4-cf8f.jpg)
Powder coaters arent going to like this! :-(
(http://img.tapatalk.com/516df8df-32e9-9b34.jpg)
Shinny!!
(http://img.tapatalk.com/516df8df-3320-329c.jpg)
More to follow...
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That was suitably 'orrible enough to warrant Cafing
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Looks like Dunstall headers with a can grafted on.
I've got this hanging in my barn...
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Looks like Dunstall headers with a can grafted on.
I've got this hanging in my barn...
Nice! :-)
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Liked the `slipped one in` of the Beastie, I had one 10 years ago in reddish yellow cocktail. Amazing bike, a bit on the heavy side but when on full chat it sounded lovely!! Almost painted my K3 in that colour I liked it so much! Had to sell it, I wouldn`t have still been on this earth if I hadn`t :-[
Keep on with the cafe racer project, I`ve some rearsets and flat bars for sale on fleabay, finishes on sunday. I gave up on the idea, everyone told me that the K3 was too original to go and chop and change it!!
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They are wicked bikes (XJR's) I used to ride a GSXR but got rid to save my license and my wrists, neck, back...
Sometimes I forget how much torque the bike has!! Spent a fair amount on it already, new springs, end cans, bars and tuned engine. Getting 119bhp out of it. This ones the first of the SP's (1999) I was offered £3200 for it a few weeks back but i wouldn't sell it. Has 30k on the clock.
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(http://img.tapatalk.com/516df8df-30f9-a8b3.jpg)
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Do you realise with all that polishing on the outer surface (lightening) and the paint in the centre (weighting) this is going to put some serious stress on your wheel bearing?
;D
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Do you realise with all that polishing on the outer surface (lightening) and the paint in the centre (weighting) this is going to put some serious stress on your wheel bearing?
;D
The only stress on the bearing will be ma fat ass when I get to ride the bike ;-)
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Degreased the yokes today, sanded down and painted. Also put the bolts on the wire wheel and a quick spin on the polishing mops.
(http://img.tapatalk.com/516df8df-cc9a-acd3.jpg)
(http://img.tapatalk.com/516df8df-cd00-6776.jpg)
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When you fit that nice top yoke dont forget the special washers the go on the pinch bolt in the gap to stop you overtightening and snapping the clamp
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When you fit that nice top yoke dont forget the special washers the go on the pinch bolt in the gap to stop you overtightening and snapping the clamp
Thanks for the tip Bryanj. Are the washers a standard size? If so what? There wasn't one fitted when it was dismantled.
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ooooo- errrrrr , mine doesnt have those washers fitted either. Part number 53235-300-000, looks like a bog standard washer with part of the circumference flattened off
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http://www.cmsnl.com/honda-cb550f2-super-sport-550-four-1977-england_model17121/partslist/F04.html#results
Doesn't show it on the schematic diagram? :-\
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http://forums.sohc4.net/index.php?topic=72765.0
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This is a good site for cross refernecing part numbers. The top clamp spacer is no 12 on this schematic:
http://www.motogrid.com/pages/oemparts?aribrand=HOM#/Honda/CB550F_A_(76)_MOTORCYCLE%2c_JPN%2c_VIN%23_CB550F-2000003_TO_CB550F-2010866/HANDLEBAR_%2b_TOP_BRIDGE_%2b_STEM/CB550F-76-JPN-A/2Y133900F13390004A
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Good & Bad day :-( :-)
Finally removed the engine from the frame :-). Snapped a long bolt in the process and found out these are mega £££'s :-(
(http://img.tapatalk.com/516df8df-fc8a-3a90.jpg)
Also found out the frame has a hole in it, well, a few... Which are (luckily) on the left pillion bracket so shouldn't have any effect on the frame itself.
(http://img.tapatalk.com/516df8df-fcaa-2cf7.jpg)
Having spoke to someone, it would seem cutting this section out between the frame and the mounting point then welding an identical sized tube in its place would do the trick.
The other problems to address are:
Bolt seized in frame in the front middle engine mounting point.
Rear brake lever spline seized in frame.
(http://img.tapatalk.com/1f7c48c6-0328-89ef.jpg)
Cut rear seat/fender mount off.
Weld new rear end and cross member support bracket
(http://img.tapatalk.com/1f7c48c6-02fe-9e0c.jpg)
Grind off unwanted brackets etc
Remove centre stand (which appears to be stuck!(http://img.tapatalk.com/1f7c48c6-02d6-22d3.jpg)
I got a quote of £35-50 to shot blast frame and swing arm and £80 to powder coat. Thought that was reasonable. Decided i'm going to get brand new rims as these are rusted to buggery.
(http://img.tapatalk.com/1f7c48c6-02c0-af7b.jpg)
So, any suggestions on removing the brake lever spline thingy?
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First choice for me to extract the brake pivot would be heat. Oxy acet is king but butane might do it. Failing that used engine oil, Cheap cola and repeated tapping and soaking in the above will probably sort it. Just don't get too brutal in case you mushroom the end. Twisting is also powerful so tap the leaver end of it. I used the soaking and tapping method on some trailer wheels that were rusted solid onto their hubs when heat wasn't an option because i wanted the tyres.
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First choice for me to extract the brake pivot would be heat. Oxy acet is king but butane might do it. Failing that used engine oil, Cheap cola and repeated tapping and soaking in the above will probably sort it. Just don't get too brutal in case you mushroom the end. Twisting is also powerful so tap the leaver end of it. I used the soaking and tapping method on some trailer wheels that were rusted solid onto their hubs when heat wasn't an option because i wanted the tyres.
Cheers for this. Didnt think of coke but assume the acidity in it helps break down the rust? Tried propane/blow torch but can't get it hot enough.
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I always use Plusgas and as said heat.
You could drill a small hole into the tube and fill with fluid also, it would be easy to
weld up afterwards or fit a grease nipple.
I ended up buying new rims as well, i wanted tp powdercoat the originals but the powdercoater
said they were too rusty to get a decent finnish.
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Which bolt was it? If the one that goes all the way through and holds the footrests just buy a length of stainless stud bar and put a nut each end
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Frame looks very rusty. Is it as bad as it looks..???
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Irs been painted by hand by a PO.
Sanded back several areas that look suspect but the frame is okay. Will see more when blasted.
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Ground some paint off in about 20 places with the dremel tool in the suspect areas and looks okay. It appears to be 3 or 4 layers of paint one being similar to hamerite.
(http://img.tapatalk.com/516df8df-fcac-6e07.jpg)
(http://img.tapatalk.com/516df8df-fcbb-df9c.jpg)
(http://img.tapatalk.com/516df8df-fcce-ec42.jpg)
(http://img.tapatalk.com/516df8df-fcda-7fd2.jpg)
(http://img.tapatalk.com/516df8df-fce6-3599.jpg)
(http://img.tapatalk.com/516df8df-fcf2-7bec.jpg)
(http://img.tapatalk.com/516df8df-fcfc-9bf5.jpg)
(http://img.tapatalk.com/516df8df-fd0a-c9f9.jpg)
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(http://img.tapatalk.com/516df8df-1f9b-67de.jpg)
(http://img.tapatalk.com/516df8df-1fb0-ce3c.jpg)
(http://img.tapatalk.com/516df8df-1fbc-7f87.jpg)
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wow, conidering the amount of rust on the frame and all your seized component problems it seems amazing that the stanchions have survived so well. Looking good on the front end ! ..... did that speedo drive arrive with you okay ?
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wow, conidering the amount of rust on the frame and all your seized component problems it seems amazing that the stanchions have survived so well. Looking good on the front end ! ..... did that speedo drive arrive with you okay ?
It did indeed mate. I meant to send you a message but forgot :-(
Thanks again buddy. It's just what I needed.
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I always use Plusgas and as said heat.
You could drill a small hole into the tube and fill with fluid also, it would be easy to
weld up afterwards or fit a grease nipple.
I ended up buying new rims as well, i wanted tp powdercoat the originals but the powdercoater
said they were too rusty to get a decent finnish.
Soaked in Plus gas overnight and I have about 10-15 degrease of movement when tapping with a hammer but it still won't budge.
Will soak longer and apply some heat in a day or two.
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I'm nearing the time when I have to take the plunge and start cutting pieces of the frame (CB550 restorers look away ;-)
I have bought a piece for the tail from fleabay (simply because it was easier and the welder I know hasn't got the facility to bend pipe)
I'm not sure where I need to make the cut (other than obviously the rear of the shock mounting points!)
So I fabricate/buy a seat unit first and line everything up?
Also, can't decide whether or not to chop the rear pillion footrests off as I'm undecided about rear sets or keep standard rider rests.
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Pasenger peg mounts are handy for exhaust hanger bracket mountings if that decides you one way or another
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Good point :)
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Having major trouble getting the oil filter off. PO cut a slot in the head of the bolt which I have tried using an impact screwdriver on but still not moving. Tried grip pliers etc.
The thread I believe is at the end of the shaft. Is there any suggestions how to get this off??
(http://img.tapatalk.com/b267e764-19a6-c386.jpg)
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Drill the head off, pull the housing off , then use mole grips . Just hope its not siezed
onto the housing though and it is the threads.
Looks like there is enough to get some Stillsons on the end still, the bolts knackered anyway.
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Weld a big nut on with an arc welder, the heat will travel down and the bigger hex will help
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Best way to clean an oil strainer guys???
(http://img.tapatalk.com/d/12/09/03/y7a3ezam.jpg)(http://img.tapatalk.com/d/12/09/03/urenezah.jpg)(http://img.tapatalk.com/d/12/09/03/vapybyre.jpg)
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P.s. managed to grind the head of the bolt but when doing so I had a moment! And thought I'd give it another tap with the cold chisel. Would you believe it, it freed up!
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Any thinners for the filter mate
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Bolts often come free after a bit of grinding, probably the heat, vibration and removed metal releasing that bit of tension that's holding them.
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Thanks for the advice guys. Sorted :-)
(http://img.tapatalk.com/d/12/09/04/eqaja5un.jpg)
(http://img.tapatalk.com/d/12/09/04/purepaby.jpg)
(http://img.tapatalk.com/d/12/09/04/2ezajeda.jpg)
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Quick update
Oil filter off (looks like the first time as well!!) and oil strainer cleaned. Was a right bitch as the oil filter bolt was solid! Heat, hammer, headache and chisels and finally it came free!
Oil strainer - before...
(http://img.tapatalk.com/d/12/09/04/5yta9umu.jpg)(http://img.tapatalk.com/d/12/09/04/y9u9u7et.jpg)(http://img.tapatalk.com/d/12/09/04/y5yjyguv.jpg)
And after...
(http://img.tapatalk.com/d/12/09/04/ry9y9yze.jpg)(http://img.tapatalk.com/d/12/09/04/u5e3ehyt.jpg)(http://img.tapatalk.com/d/12/09/04/e9ymudu8.jpg)
Internals look good. Very little if any wear (good 'ol Honda!)
(http://img.tapatalk.com/d/12/09/04/yra4uba9.jpg)
Frame returned back from the blasters
(http://img.tapatalk.com/d/12/09/04/uba7ezuj.jpg)(http://img.tapatalk.com/d/12/09/04/agy7uzaj.jpg)(http://img.tapatalk.com/d/12/09/04/y8y2azys.jpg)(http://img.tapatalk.com/d/12/09/04/atusy2e3.jpg)
All the rusty bits are being cut off. Haven't decided whether or not to chop off the rear footrest hangers which were going to be used for the rear sets & Exhaust hanger. I think I'll just go with standard pegs and chop them off, one is badly rusted anyway? Rear seat/mudguard mount being chopped off and this will be welded on instead...
(http://img.tapatalk.com/d/12/09/04/uvavaqy6.jpg)
Thankfully I have a friend who's a pro welder :-)
Cylinder Head cleaned, soda blasted and painted...
(http://img.tapatalk.com/d/12/09/04/aqagyde9.jpg)(http://img.tapatalk.com/d/12/09/04/u6uvegu9.jpg)(http://img.tapatalk.com/d/12/09/04/ze3y4eze.jpg)(http://img.tapatalk.com/d/12/09/04/gy9emuqy.jpg)
And that's it for now...
Watch this space! :-)
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What are you oing with the offcut of rear seat frame? I have a feeling one of my bikes is a wee bit rusted to tifoil in that area and a spare section to weld on would be eayer than fabricating a replica (done that before now)
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The rear of the frame is rotten. You may be able to see it in this(http://img.tapatalk.com/d/12/09/05/9erube7y.jpg)
It's was coming off anyway for the new horseshoe bar that's going on to take the new seat.
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nearly finished polishing hubs (http://img.tapatalk.com/d/12/09/07/ymepe7aq.jpg)
(http://img.tapatalk.com/d/12/09/07/tehuhu4e.jpg)
(http://img.tapatalk.com/d/12/09/07/bene4e5e.jpg)(http://img.tapatalk.com/d/12/09/07/ysa4a3ug.jpg)
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Very nervous today. Dropped off the frame / swing arm and rear loop to my mate (professional welder)
Won't be for a couple of weeks before its back.
Made the decision to cut the pillion brackets off to give a more naked look. Rear seat mount and mudguard mount being chopped and "U" piece being welded in its place.
Cutting the extra bits off such as, seat lock, seat hinge, centre stand brackets and some cable tidies.
When it's back it will be sanded etc prior to being Powder Coated. Want to make sure I'm 100% happy with the surface prep first.
I also ordered a new oil filter bolt, oil filter, front rim, front spoke set, front sprocket and some other little bits and bobs from David Silver Spares
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Will K4 550 rear shocks fit my F2?
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ER no such thing as a K4 550 but yes the 550 shocks will all fit
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some goodies arrived today
(http://img.tapatalk.com/d/12/09/11/u6ynuje9.jpg)
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ER no such thing as a K4 550 but yes the 550 shocks will all fit
Ah sorry I miss read it! Lol. It was 550 /4
Duh! ;-)
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frame progress... Nearly done.
(http://img.tapatalk.com/d/12/09/17/a6yry9e2.jpg)(http://img.tapatalk.com/d/12/09/17/ny6any6e.jpg)(http://img.tapatalk.com/d/12/09/17/e9uvatat.jpg)
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hey slow doon, yer overtakin me
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hey slow doon, yer overtakin me
Lol
Wheels dropped off to PC's. £60 all in, including a light bead blast.
Turnaround time 1 week :-0
Been told frame is all ready for pick up (Monday now)
Just need to assemble the wheels and do a loose assemble for the rolling chassis to check rear wheel clearance
All being well the frame can be PC'd and then the fun starts....
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(http://img.tapatalk.com/d/12/10/26/7arypa3a.jpg)
Getting there slowly
Sent from my GT-I9300 using Tapatalk 2
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...any progress on the build? Was following this one intently!
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Sorry, motorbike accident put a hold on things. Will be resuming very soon. Stay tuned!!
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Ah mate hope you're ok?
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Wow, didn't realise it's been so long...
here's a quick update as i have mainly been using the Facebook Page (purely because its easier to post on the fly)
I have since last time had the frame, chopped, welded and powder coated, wheels rebuilt, front fork rebuilt and now about to install the brake caliper, hoses and refurb the brake reservoir.
Engine is nearly ready to go in the frame, as I am limited on space at the moment i have decided to rebuild the engine in the frame!!
Hopefully that will be going in this week ish. Seat is on order, rear light and indicators ordered, bates style headlight arrived and loads of other goodies. Every single nut and bolt has been stripped from this bike!!!! I hope this long 2 years will be worth it in the end!!!
(http://img.tapatalk.com/d/14/07/23/atatata2.jpg)
(http://img.tapatalk.com/d/14/07/23/a4yravyg.jpg)
(http://img.tapatalk.com/d/14/07/23/umy7y7ej.jpg)
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Thats looking pretty damn mean sherlock, steve mcqueen style
, i like it
pete
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(http://img.tapatalk.com/d/14/07/23/edeteje4.jpg)
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(http://img.tapatalk.com/d/14/07/24/vyhy7ytu.jpg)
(http://img.tapatalk.com/d/14/07/24/janubyga.jpg)
(http://img.tapatalk.com/d/14/07/24/a2a4asyt.jpg)
(http://img.tapatalk.com[URL][/URL]/d/14/07/24/3u6y3ype.jpg)
(http://img.tapatalk.com/d/14/07/24/udyzydes.jpg)
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Engine in today. (http://img.tapatalk.com/d/14/07/25/dypasahu.jpg)
(http://img.tapatalk.com/d/14/07/25/eve9aseh.jpg)
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Glad to see you got the proffesionals helping out