Post by: Mace53 on September 21, 2016, 09:19:39 PM
Im porting this over from the .net site to the uk one. I figured it was more relevant over here, and better placed for local tips and other stuff. Just bear in mind I started this project back in October 2012, so dont expect a quick finish!
Since starting the project I bought a new house, started a new job and last year got engaged. Marriage coming next month. More bike spending after!
_____________________
Greetings everyone. Ive been reading all the topics regarding cafe racer rebuilds, and have decided to take the plunge and keep myself busy with a bike this time (i normally work on classic cars). I have therefore gone and picked up a CB500 (not sure of which k version it is) from 1975, i managed to get it all for £550 with delivery. As far as i know it has been stationary for quite a while.
Im hoping for a simple design, cheap and original and have two ideas at hand:
(http://s10.postimage.org/rtd85yc89/Inspiration_2.jpg)
(http://s10.postimage.org/4gf6nfw4p/Inspiration.jpg)
As you can see there isnt much to the bike, and ive recently stripped pretty much everything off of it in order for a complete rebuild.
(http://s17.postimage.org/spp05lhjz/DSC_0057.jpg)
(http://s12.postimage.org/px8dqmpkd/DSC_0058.jpg)
(http://s12.postimage.org/woysthejx/DSC_0059.jpg)
(http://s12.postimage.org/civauliwd/DSC_0060.jpg)
Home:
(http://s10.postimage.org/53e3cyt0p/DSC_0064.jpg)
- So my first hurdle are the carbs, and after taking off the chamber sets i had a little moment of, "oh $%£&", as you can see i have my work cut out for me!
(http://s13.postimage.org/e8h0vlbvr/DSC_0061.jpg)
(http://s13.postimage.org/jxx9fwi1z/DSC_0062.jpg)
(http://s13.postimage.org/gscnpozfr/DSC_0063.jpg)
It doesnt take a genius to figure out this is quite a serious problem, and as im new to bike restorations any advice would be much appreciated!
So theres good news -
(http://s11.postimage.org/4nt2sgfmb/DSC_0065.jpg)
But also very bad news! This 40 jet snapped inside the thread, doesnt look like i will be salvaging this one then!
(http://s11.postimage.org/dk3uwe68j/DSC_0066.jpg)
- After 1 hours bath:
(http://s11.postimage.org/kr5js9h5f/DSC_0067.jpg)
So today ive focused on grinding off those annoying little side panel mounts, and after annoying the neighbors for a while ive managed to get there in one piece.
All a man needs in his life. Flat head, massive hammer, angle grinder and a hacksaw.
(http://s8.postimage.org/o2lh2jhwl/DSC_0070.jpg)
I admit this looks like ive cut straight through the frame at a right angle, i can assure you i havent!
(http://s8.postimage.org/6qppuudt1/DSC_0072.jpg)
Top stuff
(http://s8.postimage.org/d6yokxmcl/DSC_0077.jpg)
(http://s18.postimage.org/hwrxbtkl5/DSC_0078.jpg)
However as always i have bad news:
(http://s18.postimage.org/8q9mojfcp/DSC_0079.jpg)
(http://s18.postimage.org/udykyzfqx/DSC_0080.jpg)
I was wondering why they were stiff!
You can use a rack of PD carbs from a K model ( like the last pic I posted here) but , you will need the K model intake manifolds and pucks because they are larger than the carbs that came on your bike. You will also need the correct Throttle cables from the K and possibly a choke control cable and bar set up .
Cheers for that info, i have no doubt that i may end up using these.
So I admit that ive not been best at keeping people updated with progress on my build :-\
Having bought a new house, moved into a new area, starting a new job and getting engaged, sadly the build got shelved for a while. But this summer I got back into it after I persuaded my dad to buy this:
(https://s31.postimg.org/gxi9zuwe3/DSC_0050.jpg)
http://www.kottmotorcycles.com/builds/2015/7/10/-grey-and-maroon
Needless to say, he is no longer a Beemer snob!
______
So a few pics of where I am at:
(https://s32.postimg.org/pgxyy9qlh/DSC_0060.jpg)
(https://s32.postimg.org/nfysgo145/DSC_0059.jpg)
The only items remaining from the original bike are the frame, front forks and the front and rear wheel hubs.
Everything, and i mean everything else got binned (carbs, wiring, wheels etc)
I have lovely brand new rims/ spokes/ tyres, headlight (to be painted), rear shocks, mini gauges, front brake caliper , clip ons, and i even picked up a used tank from a 500 twin. The front forks have progressive springs installed in them and they are damn stiff now!
(https://s32.postimg.org/oo4aj54md/DSC_0055.jpg)
(https://s31.postimg.org/8xvzgrpqj/DSC_0058.jpg)
Im even debating on how I want the speedo mounted, i've settled on this position;
(https://s32.postimg.org/dlfs0a9x1/DSC_0062.jpg) Thoughts?
Once I have the rolling frame sorted (just finishing up some painting on the brake disc and rear axle), I am going to be doing my very own ultrasonic cleaning of a new set of carbs I bought from a CB550. Theyre already in pretty good condition, only a few minor residues of fuel in those hard to reach places.
An old picture on my new carb cleaning progress.
(https://s31.postimg.org/rrhsdrnyj/mms_20160802_135550.jpg)
Manky disc!
(https://s32.postimg.org/l1k0ds8x1/DSC_0064.jpg)
Brake disc covered and ready for some primer!
(https://s31.postimg.org/ch8qewb23/DSC_0068.jpg)
More to follow over the next few weeks (ive got a week off work now 8) )
So I've made the decision to split the engine myself. I figured with a bit of common sense and patience I can do the job myself.
(http://uploads.tapatalk-cdn.com/20160910/780839b84a421a38e7fcf799c38f027a.jpg)
I also decided at a spur of the moment to cut the rear foot peg mounts off.
(http://uploads.tapatalk-cdn.com/20160910/faa4e81e2011495138540bfeaa145645.jpg)
(http://uploads.tapatalk-cdn.com/20160910/bd6b5e4cecd605a8007c5f06517ff41c.jpg)
(http://uploads.tapatalk-cdn.com/20160910/871d17c5ea13736b32db24651daf65f8.jpg)
(http://uploads.tapatalk-cdn.com/20160910/c9f70020c7b12d8716a00ce6ecac2d6d.jpg)
(http://uploads.tapatalk-cdn.com/20160910/0381a788a5a9ab777950720ceb78fafb.jpg)
I got everything attached to the engine blasted, and I'm going for an aluminium look with gloss black on the cylinder block.
(http://uploads.tapatalk-cdn.com/20160910/41fb75e4e88d58153faa3d0c989cf3c6.jpg)
I'm also doing a 1mm overbore due to some pitting damage. I tell you what there aren't very many kits for the 500/4. Lots for the 750, 550 and 450. But not many for mine. I had to get one ordered from Japan. I was going to go for the 4mm overbore bringing it up to 553cc, but I bottled it on the price
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So I've been quite busy over the last few weeks. Since getting the engine blasted, the 57mm piston kit has arrived from Japan.
(http://uploads.tapatalk-cdn.com/20160920/645d97b3461fba379f4c60e18da5c1f3.jpg)
(http://uploads.tapatalk-cdn.com/20160920/99b93f70956f4763c43212f31d96a479.jpg)
Furthermore, it's amazing how indecisive I've been about how I want the engine to look. I ended up painting the crank case and cylinder head in aluminium, but I wasn't happy with the finish. So I went and stripped it all off. I've now painted it black, and I'm going for a high polish finish on the clutch and sprocket covers.
(http://uploads.tapatalk-cdn.com/20160920/f3cbd78956de58e79248d99219d4d085.jpg)
(http://uploads.tapatalk-cdn.com/20160920/2ad46238728bc0c296348052cbc758a8.jpg)
(http://uploads.tapatalk-cdn.com/20160920/2be78941502b04a4957643e355085887.jpg)
(http://uploads.tapatalk-cdn.com/20160920/5aac1862c2191dd22c31a834b424f79c.jpg)
The next task is to get the cylinders overbored so I can start to rebuild the engine in the frame.
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Post by: Mace53 on September 21, 2016, 09:23:33 PM
I got a load of truly awesome sisal mops etc from thepolishingshop.co.uk along with some polishing compounds, and here is the before during and after shots.
(http://uploads.tapatalk-cdn.com/20160921/fbaa5607d98f8c401ffa0576d320ee88.jpg)
(http://uploads.tapatalk-cdn.com/20160921/13b3f19528a0860e85a6b1fffc086d1b.jpg)
(http://uploads.tapatalk-cdn.com/20160921/b80db18c2dc9d2056e9d31a0dfdd7444.jpg)
(http://uploads.tapatalk-cdn.com/20160921/92602be47834c97f2e62be6140f7bb62.jpg)
This stuff really really is from heaven. I cannot rate it highly enough.
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Post by: petermigreen on September 21, 2016, 09:34:15 PM
Post by: Mace53 on September 22, 2016, 07:55:02 AM
Don't whatever you do fit the PD carbs off the CB550K3, more trouble than they are worth AND the 500 carbs are far easier to source and TBH are better carbs anyway, maybe not as economical but I suppose that isn't a problem anyway.Why so? They're all I've got now as the original 500 ones were badly badly damaged. Is it the jetting that's an issue? I'm planning on running a 4-1 with the pod filters.
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Post by: hairygit on September 22, 2016, 08:11:14 AM
Post by: JamesH on September 22, 2016, 09:14:40 AM
Post by: Mace53 on September 22, 2016, 05:51:13 PM
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Post by: Mace53 on September 22, 2016, 06:22:16 PM
(http://uploads.tapatalk-cdn.com/20160922/7213b50d5ae79646089aa2e9535c493d.jpg)
(http://uploads.tapatalk-cdn.com/20160922/e1c466ae9adde40c2f70ae089b3d1248.jpg)
Here are my carbs. When I bought them they said they were the 550 ones, but I can remember which. Anyone know for sure which they are?
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Post by: Mace53 on September 22, 2016, 06:34:15 PM
(http://uploads.tapatalk-cdn.com/20160922/e39aea9abe6c9836c18b77645f4e2647.jpg)
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Post by: SteveD CB500K0 on September 22, 2016, 07:29:08 PM
Steve
Post by: Mace53 on September 22, 2016, 09:48:56 PM
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Post by: Mace53 on September 24, 2016, 06:53:56 PM
(http://uploads.tapatalk-cdn.com/20160924/28cc89c5d4574f55d88b9c4091772cb4.jpg)
(http://uploads.tapatalk-cdn.com/20160924/a0d6ae9f894e31da62cfb1e4d8a1e12b.jpg)
(http://uploads.tapatalk-cdn.com/20160924/c6d8a5057e50b565d1e1211ca4dc1bb4.jpg)
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Post by: Mace53 on September 26, 2016, 05:50:18 PM
(http://uploads.tapatalk-cdn.com/20160926/17d76be5025576ef2f2bdc8ab76343f7.jpg)
(http://uploads.tapatalk-cdn.com/20160926/ed7f7f59b6126812821e4123dd14f1cd.jpg)
(http://uploads.tapatalk-cdn.com/20160926/4cf02ee2528f2fce08236bb6be491fd7.jpg)
(http://uploads.tapatalk-cdn.com/20160926/7d869078faa65d4b70481f0c589d3631.jpg)
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Post by: Chris400F on September 26, 2016, 08:12:20 PM
It would tidy things up if you could lose the handlebar clamp and instrument mount brackets, as long as that still left a way of mounting your speedo.
Post by: Mace53 on September 28, 2016, 05:44:49 AM
Possibly the name im going to give her....
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Post by: Mace53 on October 10, 2016, 11:20:49 PM
(http://uploads.tapatalk-cdn.com/20161010/984d5edaa958772b6c0143dee1e6c373.jpg)
So I did this instead.
(http://uploads.tapatalk-cdn.com/20161010/8f71377eebbe49ebaeaab2ad65976063.jpg)
(http://uploads.tapatalk-cdn.com/20161010/0be1a92e903d6d3cd6d09d3ceec18086.jpg)
(http://uploads.tapatalk-cdn.com/20161010/550b65a81c63c30ba1a5707ff05371df.jpg)
Oh and I assembled the engine casings to get a feel for what the colours will look like in the frame. Bear in mind the unpainted will be painted black one I have it overbored.
(http://uploads.tapatalk-cdn.com/20161010/38a260d878262415e0f8a660de796192.jpg)
(http://uploads.tapatalk-cdn.com/20161010/f3442476da5a71fa9de11315622c3bce.jpg)
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Post by: Mace53 on March 16, 2017, 04:21:06 PM
(https://uploads.tapatalk-cdn.com/20170316/7536986671dda39dda2d2fa696699375.jpg)
(https://uploads.tapatalk-cdn.com/20170316/5f9c5f565ede9e3abbbdc4dccb8b7c5b.jpg)
(https://uploads.tapatalk-cdn.com/20170316/3fb638ec7aba6d8cf16b1d04e09d4f95.jpg)
Slow progress
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Post by: paul G on March 16, 2017, 04:49:19 PM
Post by: cantarauk on May 13, 2017, 06:46:51 PM
Great job so far keep it going. Two questions - what shocks are you using and then who did your seat cowl( loving it)
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Post by: Mace53 on May 14, 2017, 04:56:17 AM
Hi MaceThanks. I built the seat myself from sheet steel and tube bars in a ring roller. I then welded it together and put two 6mm bolts on the underside. It was the first time but I'm happy with the overall stance of the seat.
Great job so far keep it going. Two questions - what shocks are you using and then who did your seat cowl( loving it)
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I'm afraid that I can't remember for the life of me where I got those rear shocks. I think I got them back in 2012 so my memory has failed me on that one!
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Post by: Mace53 on May 14, 2017, 05:02:22 AM
(https://uploads.tapatalk-cdn.com/20170514/79dd7615ea61ad43c43ce6dce9b6cda3.jpg)
(https://uploads.tapatalk-cdn.com/20170514/98b7290cbca881ccb24b735d797e90d4.jpg)
(https://uploads.tapatalk-cdn.com/20170514/9385342973da6bf6afc2ff31e70f49b8.jpg)
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Post by: Niko on May 15, 2017, 06:37:36 PM
(https://uploads.tapatalk-cdn.com/20170316/9dea0d0bc53d9f81875ac3c75dba70b3.jpg)(https://uploads.tapatalk-cdn.com/20170515/4fff4fdd8d8eded0a934d9e239e081e0.jpg)
(https://uploads.tapatalk-cdn.com/20170316/7536986671dda39dda2d2fa696699375.jpg)
(https://uploads.tapatalk-cdn.com/20170316/5f9c5f565ede9e3abbbdc4dccb8b7c5b.jpg)
(https://uploads.tapatalk-cdn.com/20170316/3fb638ec7aba6d8cf16b1d04e09d4f95.jpg)
Slow progress
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Finished mine last week....just waiting for registration....
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Post by: Niko on May 15, 2017, 06:39:17 PM
(https://uploads.tapatalk-cdn.com/20170515/7a9126f045ad7ee4cac129796e0fb534.jpg)(https://uploads.tapatalk-cdn.com/20170316/9dea0d0bc53d9f81875ac3c75dba70b3.jpg)(https://uploads.tapatalk-cdn.com/20170515/4fff4fdd8d8eded0a934d9e239e081e0.jpg)
(https://uploads.tapatalk-cdn.com/20170316/7536986671dda39dda2d2fa696699375.jpg)
(https://uploads.tapatalk-cdn.com/20170316/5f9c5f565ede9e3abbbdc4dccb8b7c5b.jpg)
(https://uploads.tapatalk-cdn.com/20170316/3fb638ec7aba6d8cf16b1d04e09d4f95.jpg)
Slow progress
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Finished mine last week....just waiting for registration....
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Post by: Mace53 on May 15, 2017, 08:04:28 PM
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Post by: Niko on May 15, 2017, 08:11:31 PM
Looking good. Are they bullet holes on the tank?
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Yes.....I live in Stoke.
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Post by: Niko on May 15, 2017, 08:12:40 PM
(https://uploads.tapatalk-cdn.com/20170515/28f8f0c054540007a6495dffab8d3373.jpg)Looking good. Are they bullet holes on the tank?
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Yes.....I live in Stoke.
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Post by: cantarauk on May 19, 2017, 08:47:31 PM
Post by: Seabeowner on May 26, 2017, 09:30:33 AM
If they are TEC shocks on the back they are great for original look, but a bit soft. And I read somewhere that if you remove the front guard then a lower brace across the forks was recommended.
Post by: Mace53 on September 03, 2017, 09:27:16 AM
I've finished rebuilding the engine myself with brand new stainless Allen bolts and seals etc. I found the lower crankcase by far the hardest part. Getting the gear selectors in was tough.
(https://uploads.tapatalk-cdn.com/20170903/d4e8c2c52cd3080d7b03b5ae22d0b0f3.jpg)
(https://uploads.tapatalk-cdn.com/20170903/cfd7a527ef57e75c31381f405598c850.jpg)
However I stripped an already damaged thread on the lower crankcase on the lower oil cap on the offside of the bike. Given that it appears to be just a drain plug I have slapped some high temp jb weld in there for the time being.
(https://uploads.tapatalk-cdn.com/20170903/747198cf2d87f4a6ef93c59065b7ee02.jpg)
I'm now in the process of building the wiring harness myself. New pamco electronic ignition went on which I got from the good blokes from 4 into 1.
(https://uploads.tapatalk-cdn.com/20170903/834edccd9e8e355ab0b5b703d1794e49.jpg)
(https://uploads.tapatalk-cdn.com/20170903/b5c0651fe0887ebe28dc378a8dc88e69.jpg)
Not long now.
(https://uploads.tapatalk-cdn.com/20170903/0b3108deb97d99a78895cd4a0d3a74f7.jpg)
(https://uploads.tapatalk-cdn.com/20170903/8f4b1fb9ac26f4944abadc276114ea96.jpg)
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Post by: hairygit on September 03, 2017, 09:43:30 AM
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Post by: Mace53 on September 03, 2017, 09:50:58 AM
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Post by: hairygit on September 03, 2017, 10:32:46 AM
Post by: Mace53 on September 03, 2017, 10:58:44 AM
The high temp jb weld is rated at 232 degrees c on continuous heat. Given that Homdaman rates this section of the engine at around 60 degrees then hopefully the weld should stand.
Provided it isn't in a pressurised oil canal. I'm hoping someone might know this.
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Post by: hairygit on September 03, 2017, 11:02:47 AM
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Post by: Seabeowner on September 03, 2017, 12:33:49 PM
Post by: Trigger on September 03, 2017, 12:47:00 PM
To get engine oil bungs out, you need a lot of heat and I use a Metrinch socket that grabs the flat surface of the Hex, not something you would find at Halfords or your local car boot ;D
Post by: Seabeowner on September 03, 2017, 01:13:06 PM
But just answered my question above.
The hex length on the cap is very short and the ally soft as ^%$t.
But using the chunky old Vessel impact driver which has a 1/2 drive with a good fitting 14mm HEX socket (not 12 point!) just removed two from an old engine reasonably easy. (and one was already chewed.)
But pretty impossible with engine in frame.
Post by: Mace53 on September 03, 2017, 01:36:58 PM
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Post by: Bryanj on September 03, 2017, 02:32:25 PM
Post by: Trigger on September 03, 2017, 03:11:55 PM
Post by: Mace53 on September 12, 2017, 07:53:10 PM
Hoping to get her started this week.
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Post by: petermigreen on September 12, 2017, 09:08:07 PM
Peter
Post by: Mace53 on September 21, 2017, 03:56:02 PM
After over 20 years sat rusting and feeling sorry for herself, I have finally got the old girl started! Very chuffed.
She runs really well, and sounds great with the 4 to 4 drag exhaust I made up.
(https://uploads.tapatalk-cdn.com/20170921/d2a4cca056e23ba455b5f21d0a0f2648.jpg)
Carbs are all synced and work great together.
She fires up straight off the kick even on a cold start.
(https://uploads.tapatalk-cdn.com/20170921/87ea9e6490bd9579d218a100eee6f7cf.jpg)
However, I didn't think that my first engine rebuild would go smoothly and I do have a problem which im struggling to figure out.
The #1 cylinder is smoking quite a bit but only one the bike is fully warmed up. Nothing on cold idle or light revving from cold. Its a combination of blue and grey smoke and is definitely an issue.
Compression tests across all 4 cylinders :
1- 150
2- 155
3 - 150
4 - 158
After 5 mins of idle and revving these pictures are what I discovered:
Still image from a video I took.
(https://uploads.tapatalk-cdn.com/20170921/30451c39b045415972dc1e834d8d9435.jpg)
End of the exhaust.
(https://uploads.tapatalk-cdn.com/20170921/5b6b49230fba26eaaaaf29314173de2f.jpg)
Exhaust valve.
(https://uploads.tapatalk-cdn.com/20170921/f4b25f0eb39785082e76c24f786152fc.jpg)
Wet oil from the exhaust hole.
(https://uploads.tapatalk-cdn.com/20170921/5ad820af2e5f1a4568756a44bd370255.jpg)
But the spark plug looks ok?
(https://uploads.tapatalk-cdn.com/20170921/4911d14bab6bada37a54fc653e1e7e5b.jpg)
(https://uploads.tapatalk-cdn.com/20170921/c80efe757e7f6c2ee770e4c298b08521.jpg)
(https://uploads.tapatalk-cdn.com/20170921/354aad7910a7da4ff71b7faf03f43ef1.jpg)
I've been reading reading checking and struggling to figure out what the primary cause may be.
I'm running the carbs lean on 3 turns out due to the pods and 4-4 exhaust.
The previous topics on here point to leaking oil around the piston rings and leaking oil from the valve stem seals. But both are brand new.
I'm running an electronic ignition with brand new dr8es ngk plugs and ngk caps and leads.
Any ideas at all?
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Post by: Bryanj on September 21, 2017, 03:57:54 PM
Post by: Mace53 on September 21, 2017, 04:01:51 PM
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Post by: Bryanj on September 21, 2017, 04:03:10 PM
Post by: Tomb on September 21, 2017, 04:16:52 PM
Check the actual valve stem where it sits in the guide within the exhaust port.
Post by: Mace53 on September 21, 2017, 04:40:39 PM
I might just redo the entirety of the exhaust valve, stem and guide, just to be safe.
Is it an easy job to change the guides yourself?
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Post by: Tomb on September 21, 2017, 04:58:41 PM
Post by: Mace53 on September 21, 2017, 05:52:42 PM
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Post by: Trigger on September 21, 2017, 07:17:59 PM
Ah that makes perfect sense. When you explain it like that the exhaust valve does sound like the culprit. Could it also be the inlet as well?
I might just redo the entirety of the exhaust valve, stem and guide, just to be safe.
Is it an easy job to change the guides yourself?
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You need a fair bit of tooling and the seats need to be re ground as the heat you need to put valve guides in sometimes distorts the seat a little.