SOHC.co.uk Forums > CB500/550
500K2 engine rebuild. Newbie questions
ebmbiker:
Good afternoon chaps,
Newbie member JB here,
I've bought a 500K2 project bike that's already been dismantled by the previous owner 10 years ago. Including the engine.
I know I need new main crank shells as I've only got 4 of the originals, the rest are missing. Besides seals and gaskets, what else am I going to need whilst I'm doing it? It's been decades since I've done any engine building, and those were 2 stroke singles. So what's the list of 'whilst you're in there' things to do?
Cheers, JB
philward:
Apart from the piston/rings checking (cruzinimage on ebay are quality/cheap) change primary chain/rubber dampers (kawasaki chain is same and cheaper) (http://www.sohc.co.uk/index.php/topic,25977.msg238189.html#msg238189). Camchain (DID) and use genuine camchain train rollers/tensioners. Check gearbox bearings but generally serviceable. Check clutch pushrod as they are known to break (NurseJulie usually stocks them)
Check cams/rockers/bearings for wear.
Ex Honda technicians will be along shortly with detailed advice
Oddjob:
Phil pretty much nailed it.
Buy a set of JIS screwdrivers, most important thing. Also see if you can find them in socket version.
Camchain, genuine no longer available unless your lucky, I'm looking into whether you can use a DID 219FTH chain instead as it's stronger than the standard DID chain and cost is very low considering. Check tensioner blade, guide is usually ok, check tensioner adjuster screw slot, see if it's mangled.
Primary chain, buy the Kwack chain it's 92057-1011, half the price of Hondas and the same chain. Check the oil gallery running under the chain to see if the chain has been hitting it, replace the damper rubbers inside the primary drive hub, you'll need an impact driver to open that.
Check all roller bearings for notchiness and general motion. There are only 4.
Replace all o-rings and seals if possible, you'll need a rotor tool to remove the rotor to replace the one behind it or borrow one.
Check camshaft for wear on lobes and wear on journals, check the head for the wear as well. Check cam followers for wear, if in doubt post a pic on here for advice.
DON'T use an impact driver to remove the tacho drive housing, especially the one holding the cable in, you'll break the housing most likely, check to see if it comes out intact, a lot don't.
Check sump bolt thread in oil pan.
If in doubt, take a picture before dismantling, remove in sequence then reassemble after removal to make sure you know how it goes, use elastic bands if possible to keep things together. Watch when removing the gearbox from the cases, the ends will fall off if your not careful meaning you can't be sure how they went on.
Sounds like a handful but TBH these engines are easy to work on.
murdock:
estamos ansiosos esperando.
lo primero que necesitas es el manual de servicio
y revisar todo completamente
we are anxiously waiting.
the first thing you need is the service manual
and check everything out completely
ebmbiker:
--- Quote from: Oddjob on February 09, 2022, 03:15:40 PM ---Phil pretty much nailed it.
Buy a set of JIS screwdrivers, most important thing. Also see if you can find them in socket version.
Camchain, genuine no longer available unless your lucky, I'm looking into whether you can use a DID 219FTH chain instead as it's stronger than the standard DID chain and cost is very low considering. Check tensioner blade, guide is usually ok, check tensioner adjuster screw slot, see if it's mangled.
Primary chain, buy the Kwack chain it's 92057-1011, half the price of Hondas and the same chain. Check the oil gallery running under the chain to see if the chain has been hitting it, replace the damper rubbers inside the primary drive hub, you'll need an impact driver to open that.
Check all roller bearings for notchiness and general motion. There are only 4.
Replace all o-rings and seals if possible, you'll need a rotor tool to remove the rotor to replace the one behind it or borrow one.
Check camshaft for wear on lobes and wear on journals, check the head for the wear as well. Check cam followers for wear, if in doubt post a pic on here for advice.
DON'T use an impact driver to remove the tacho drive housing, especially the one holding the cable in, you'll break the housing most likely, check to see if it comes out intact, a lot don't.
Check sump bolt thread in oil pan.
If in doubt, take a picture before dismantling, remove in sequence then reassemble after removal to make sure you know how it goes, use elastic bands if possible to keep things together. Watch when removing the gearbox from the cases, the ends will fall off if your not careful meaning you can't be sure how they went on.
Sounds like a handful but TBH these engines are easy to work on.
--- End quote ---
Cheers Oddjob, exactly what I wanted to know. Unfortunately, the engine was already in pieces when I bought the bike so I didn't have the opportunity to photograph and label things. The cam lobes, followers and journals are all smooth with no visible damage. I can see that the primary chain has marked the case, but not much. I'll post a photo of it once I'm back in the workshop.
Cheers, JB
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