Honda-SOHC
SOHC.co.uk Forums => CB500/550 => Topic started by: Dangerousdave999 on December 14, 2014, 03:33:28 AM
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Hi guy's,
Starting the first part of my winter project today which is a engine rebuild and a twin disc conversion for my CB550K3.
Made some good progress today with the carbs, tank, seat, exhaust, battery, side covers etc all off in a neat pile.
Drained the oil from the engine ready to remove it.
Fabricated up a stand from some lawn mower blades ready to take the engine when its removed. :P
Still trying to decide the best route for the engine build.
Do I go big bore and buy all the bits from Dynoman and WebCam in america at considerable cost.
Or take it to likes of Pacre or D-E engineering here and get them to work some magic into it.
Anyone with experience on the matter would be great!
On the brake side of things I received my other brake arm and calliper of eBay. :o
Apart from the pad being stuck in the calliper and the arm pivot pin being stuck solid. :-[
They weren't in bad condition a bit corroded but what do you really expect from second hand parts.
I managed to break loose the pad and connect the calliper to my old master and the piston came right out. ;D
I will need to buy a new seal and piston for the calliper and a new adjuster screw and spring for the arm.
As for the arm I used a file to enlarge the hole and get the pin to fit smooth without catching.
Thats it for my first post on the build.
Next up I will be drilling the discs when the other one arrives, off ebay again!
Showing you my interesting choice of upgraded master cylinder for the conversion.
As well as removing the engine and doing some preliminary checks.
Pictures will come soon when I get Photobucket running. (It does not work)
Whats the best way to compress images on a Mac?
Although I didn't today I hope to be video documenting the process and will post links to them on youtube.
Any questions and comments welcome.
David
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[attach=2]
oops put it in twice but her she is!
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Nice project david, twin disc is a good upgrade on these bikes, i bought some stuff from dynoman a few years back , its the same old story customs and postage make it an expensive option, all the good places seem to be in the US
Pete
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Sounds interesting.
I have used the big bore 600cc kit from Cruzinimage before on a couple of re-builds. Not a bad kit for £75. Frank in Germany does the stainless steel piston for those calipers with the original seal at a very good price.
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Loving that exhaust.
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Right there Pete after a rear guard saw one and the post charge is twice as much as the guard think not in this case will wait
Cheers
Bitsa
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Right there Pete after a rear guard saw one and the post charge is twice as much as the guard think not in this case will wait
Cheers
Bitsa
Bitsa, Rear chain guard? I have one of those in alright condition!
David
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David
Thanks for your reply but no mate after the chrome rear mud guard sorry should have said that
Cheers
Bitsa
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Thanks for your reply but no mate after the chrome rear mud guard sorry should have said that
I have one of those to :P
As you can see in the picture of my bike its a decent one!
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[attach=1]
lawnmower blade bike stand
[attach=2]
ebay calliper
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Okay well.. Update.
Im going full steam ahead and the bike has been stripped down completely!
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Sounds interesting.
I have used the big bore 600cc kit from Cruzinimage before on a couple of re-builds. Not a bad kit for £75. Frank in Germany does the stainless steel piston for those calipers with the original seal at a very good price.
Would frank in Germany have these now? If so how do I get in touch with him!?
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Build is being put on hold for now whilst I finish my third year at university. :-[
I have a aluminium tank and seat on order and will I update when I receive those.
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Sounds interesting.
I have used the big bore 600cc kit from Cruzinimage before on a couple of re-builds. Not a bad kit for £75. Frank in Germany does the stainless steel piston for those calipers with the original seal at a very good price.
Would frank in Germany have these now? If so how do I get in touch with him!?
Frank is out of stock at the moment. Here is a link for ref: > http://www.ebay.co.uk/itm/HONDA-CB-500-CB550-CB-750-Four-K0-K1-K7-F1-F2-Zundkontakte-Set-contact-points-/131149453878?pt=DE_Motorradteile&hash=item1e891dda36
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650 engine will slot straight in!
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650 engine will slot straight in!
If I had the money to I would.
Or build a engine with a cam, head flow, CR carbs etc.
Apart from I only have my silly restricted licence here in the uk :( so I'm limited to 46.6hp for a year and a half..
i suppose the police can't tell ;)
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The police can't tell...
However, if you have an accident, your insurance will be void and that's a far more serious offense than breaking an engine power restriction. £300 + 6 points (and max of £5k if it goes to court) vs £100 + 3 points.
Edit: just checked with the boss. Its up to £5k and 8 points and a discretionary ban if it goes to court.
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The police can't tell...
However, if you have an accident, your insurance will be void and that's a far more serious offense than breaking an engine power restriction. £300 + 6 points (and max of £5k if it goes to court) vs £100 + 3 points.
Edit: just checked with the boss. Its up to £5k and 8 points and a discretionary ban if it goes to court.
Yes, I never plan to break any laws and will always inform my insurers of any change I make.
Unlike some of my peers in saxo's and corsa's I have always declared upgrades I have made to my vehicles.
No wonder my first year car insurance was £3400 on a 2011 1.2 fiat punto :'(
I'll be stripping the engine down after I get the compression tests done.
New seals, gaskets, head clean and lick of paint and its going back in stock.
Might upgrade to electronic ignition if I collect some penny's from inside of the sofa :o
Waiting on a Motogadget M-Unit, M-Button and wiring kit at the moment.
I have already constructed a wiring diagram ready.
[attach=1]
[attach=2]
Also mocked up a idiot light block with LED's.
Used a pillar drill and it came out all wonky. Waiting for the milling machine to be hooked up so it can be done properly.
[attach=3]
And cut the back end of the frame off ready for the hoop.:o
[attach=4]
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Also got my new Hagon shocks come in so if anyone wants my originals send me a message.
[attachimg=1]
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Looks like we're doing similar builds! I've gathered the bits for a dual disc conversion myself and I'm also using the m-unit and m-button for my wiring - hoping it'll make it easier to wire as I'm going with full LED lighting in order to keep the power draw lower, and I think the m-unit facilitates this without the need for additional resistors for the indicators. My coils were shot so I'm going to use the dynacoils 3ohm with a Hondaman setup and resistor pack on the points. Hopefully I shouldn't have any charging issues since I've mediated the extra draw from the coils with the LED setup... have to try and see!
Will be watching to see how yours all comes together, best of luck!
I'll be stripping the engine down after I get the compression tests done.
New seals, gaskets, head clean and lick of paint and its going back in stock.
Might upgrade to electronic ignition if I collect some penny's from inside of the sofa :o
Waiting on a Motogadget M-Unit, M-Button and wiring kit at the moment.
I have already constructed a wiring diagram ready.
(Attachment Link)
(Attachment Link)
Also mocked up a idiot light block with LED's.
Used a pillar drill and it came out all wonky. Waiting for the milling machine to be hooked up so it can be done properly.
(Attachment Link)
And cut the back end of the frame off ready for the hoop.:o
(Attachment Link)
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Warning Long Post
Looks like we're doing similar builds! I've gathered the bits for a dual disc conversion myself and I'm also using the m-unit and m-button for my wiring - hoping it'll make it easier to wire as I'm going with full LED lighting in order to keep the power draw lower, and I think the m-unit facilitates this without the need for additional resistors for the indicators. My coils were shot so I'm going to use the dynacoils 3ohm with a Hondaman setup and resistor pack on the points. Hopefully I shouldn't have any charging issues since I've mediated the extra draw from the coils with the LED setup... have to try and see!
Will be watching to see how yours all comes together, best of luck!
Cool I see your in eton. I live in Camberley!
When our bikes are finished we will have to meet up at some point.
Im having/had a bit of trouble getting my motogadget stuff :'(
I ordered my M-unit, etc. about 2-3 weeks ago from Bikermart purely because they were one of the cheapest.
Also on Motogadgets website they say the M-unit V2 is not available so I didn't try to order direct.
Bikermart contacted me the next day after I ordered saying that their supplier didn't have all of it in stock.
So they had to order it direct from Motogadget.. You can see where this is going!
I was getting a bit fed up of waiting for so long and thought I will never get it because it's unavailable at Motogadget.
But today I got a email from Bikermart saying that my order has shipped.
So I'm happy now and hope to be receiving it possibly Saturday.
Bikermart don't seem to be a bad company, the contact was great and the sales guy always replied to my emailed concerns.
Just bad timing I suppose!
If your going through the same thing, I spoke to a guy at Motogadget about the main fuse the manual recommends to the m-unit.
He said this:
"Depends on your total maximum load/current.
30 A is a common size for carburator bikes.
If you bike already has a main fuse you can use this one.
If your bike originally does not have a main fuse it is not mandatory but while you are at it we recommend to use one to make it more secure."
Our bikes have a 15 A main fuse right, so I guess we just use that?
Update and Parts
Just done some more cutting of tabs, grinding and frame work today.
Have a small bit of welding to do from a bad joint repair was rusting along with some other parts.
Just waiting for the Tig to be wired up in the shop :)
Soon going to mock up the rearset position for all 6' 4" of me.
For my dual disc setup I'm using a 2002 Ducati 998 master (Bit excessive but its light, slimline and so cafe racer)
Will get steel lines made up for it.
However already found a problem in that the Honda threads are course but the newer ducati's are a fine thread.
But this can be sorted with different banjo's.
Sold my eBay calliper to get a new repo from DSS as it needed a new seal, piston and was scuffed up a bit.
I have gone for a Electrex regulator/rectifier unit. UK made and impressive build quality.
Battery hopefully will be a small Shorai LFX14A2-BS12 expensive though. And a dedicated charger would be needed.
Haven't decided on keeping my coils and points or upgrading to electronic.
The bike ran so well on its originals anyway I think I will leave them in for now.
LED indicators and possibly the headlight if I can get my hands on the 7" Truck-lite but £220 is stopping me so far.
I'm thinking about custom making a rear LED light. There's just nothing I really like that will fit my vision I suppose.
Holtworks aluminium tank and seat.
Bike will be a sort of 60's race replica but not. Excuse the drawing skills but this is my idea.
[attach=2]
Engine rebuild will commence soon as I have now done a compression test! But its not good news :'(
Book says 170 psi.
I got:
Cyl 1 - 160
Cyl 2 - 165
Cyl 3 - 155
Cyl 4 - 120
So new rings and a good lapping is in order.
Also discovered that this bit below (Timing plate?? don't know the technical term oops!)
[attach=1]
Has its two teeth missing!! :-\
Not the end of the world as long as I can get the nut that fits on top square so it does not upset the crank.. (almost impossible)
Anyone with a spare it would be greatly appreciated.
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I've gathered the bits for a dual disc conversion myself
Hi,
What parts i need to do a dual disc conversion for my stock CB550k 1978?
[/quote]Also got my new Hagon shocks come in so if anyone wants my originals send me a message.
I just ordered a set for my CB,...i think are Hagon Road. Is the same model as yours?
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Mihai, first you will need a fork that has the pivot arm mounting points on it ( i can not remember what type of forks you have ?)
You will need a second disc, a pivot arm, caliper, double banjo bolt, 6 longer bolts that hold the disc on, a brake line, a larger master cylinder and you must convert the speedo drive plate. I think that is it.
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In other words get your ready rubs out ;)
Cheers
Bitsa
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In other words get your ready rubs out ;)
Cheers
Bitsa
What are you going on about Bitsa ? A double banjo bolt in stainless is only £4 ;D ;D ;D
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In other words get your ready rubs out ;)
Cheers
Bitsa
Mihai, first you will need a fork that has the pivot arm mounting points on it ( i can not remember what type of forks you have ?)
You will need a second disc, a pivot arm, caliper, double banjo bolt, 6 longer bolts that hold the disc on, a brake line, a larger master cylinder and you must convert the speedo drive plate. I think that is it.
Got it!
I dont now what type is my fork. Its a CB550k 1978 US model.
This is the fork:
http://postimg.org/image/t68t6h0m9/
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I also don't know what it's called, but I think I might have a spare for you... let me have a dig this evening.
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In other words get your ready rubs out ;)
Cheers
Bitsa
Mihai, first you will need a fork that has the pivot arm mounting points on it ( i can not remember what type of forks you have ?)
You will need a second disc, a pivot arm, caliper, double banjo bolt, 6 longer bolts that hold the disc on, a brake line, a larger master cylinder and you must convert the speedo drive plate. I think that is it.
Got it!
I dont now what type is my fork. Its a CB550k 1978 US model.
This is the fork:
http://postimg.org/image/t68t6h0m9/
looking at the pic,the right fork leg looks ready to take parts for extra disc,
just compare with the left hand leg around the caliper/mudguard mounting,they should be mirror images of each other,
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Trig
To do a dual front brake is only 6 quid you say.Does that inc disc bkt caliper etc or did I miss something as at that the mo I have things on my mind? ;)
Cheers
Bitsa
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Trig
To do a dual front brake is only 6 quid you say.Does that inc disc bkt caliper etc or did I miss something as at that the mo I have things on my mind? ;)
Cheers
Bitsa
Yes, you missed the word Banjo bolt £6 ;D ;D ;D
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Oh right sound ;)
Cheers
Bitsa
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I also don't know what it's called, but I think I might have a spare for you... let me have a dig this evening.
That would be great Thanks!
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Long time no post!
Kind of a project update i guess!
I have some CB550 Hagon shocks for sale if anyone is interested. They will be in the members 4 sale area.
Photos of my project are updated regularly on my Instagram account @DDM_Historics with the #cafeproject550ddm for the complete album.
Received my aluminium tank and seat at the end of last year.
Mocking up and welding tabs at the moment.
Engine has been rebuilt and refreshed.
Will give a better update soon.
Cheers
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http://s90.photobucket.com/user/Dangerousdave999/story
I have uploaded all my photos to Photobucket as well.
Too time consuming to re size them all, spending as much time as possible getting the bike ready for the summer.
Still trying to work out what to call it..
A CR750 replica but a 550, a CR550 or a RC550? ;)
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Just to make you jealous..
[attachimg=1]