SOHC.co.uk Forums > CB500/550

Is there a correct order for tackling a Restoration Project?

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Bryanj:
The rebuild is always a good excuse for more chinese takeaway

McCabe-Thiele (Ted):
I agree, you can never take too many photos.
Unless the bike is unmolested you can't be sure things were completely original.

When I went to Stafford Show last spring I was miffed that I did not find a 250 or 400 NA Super Dream on display to assist with my build.

Murf:
I’m in the middle of a 550 rebuild and it’s interesting to think about my approach. It was never planned as a full rebuild, but starting work on it made me realise how bad the bike was, so I turned it into a full rebuild one day by taking it to pieces, so not much planning there. I definitely did not take enough photos which has cost me time but has given my brain cells a good workout.

My rebuild method has been breaking it down into small projects, the projects aren’t random but are related to the order I am working to. I do deviated occasionally to give myself a change when the bit I am working on isn’t going well,  or if I am waiting for parts.  I do try to keep closely to my rebuild plan though. 
An individual project can be something small like cleaning polishing and painting the underside of a mudguard, fitting it would then be a separate project. Or it could be bigger project like rebuilding the forks and all their associated parts. Eventually all the small front end projects will result in the front end being rebuilt. However by making it into small projects you are continually having results which make you feel good and that you are getting somewhere.

Neilw:

--- Quote from: Murf on March 19, 2026, 11:53:19 AM ---I’m in the middle of a 550 rebuild and it’s interesting to think about my approach. It was never planned as a full rebuild, but starting work on it made me realise how bad the bike was, so I turned it into a full rebuild one day by taking it to pieces, so not much planning there. I definitely did not take enough photos which has cost me time but has given my brain cells a good workout.

My rebuild method has been breaking it down into small projects, the projects aren’t random but are related to the order I am working to. I do deviated occasionally to give myself a change when the bit I am working on isn’t going well,  or if I am waiting for parts.  I do try to keep closely to my rebuild plan though. 
An individual project can be something small like cleaning polishing and painting the underside of a mudguard, fitting it would then be a separate project. Or it could be bigger project like rebuilding the forks and all their associated parts. Eventually all the small front end projects will result in the front end being rebuilt. However by making it into small projects you are continually having results which make you feel good and that you are getting somewhere.

--- End quote ---

Its exactly how mine is going, didn't plan on a full strip down, but now i'm here i'm committed to following through - and actually i found stuff that was definatley dodgy,/rotten which i wouldn't have if i had stripped it all down.

McCabe-Thiele (Ted):
Going back to the original question my build log https://www.sohc.co.uk/index.php/topic,23291.0.html shows my rebuild order, 32 pages is a lot to go through.

I bought a bike ramp, I was working alone aside from the engine lift in & out so a lot was based around the logistics of frame stability on the ramp. Having a working brake when I needed to take the engine less wheeled frame off the ramp to turn it round made the process safer.

Fitting the rear brake pivot before the rear swing arm/suspension was in place, lastly its much easier to fit the carbs then build backwards, fitting the air box & the rear plastic fender section. Pretty sure I might have removed the rear wheel to make it easier. Certainly worth ensuring the carb floats are sealing before you fit the carbs by using an auxilliary petrol tank.
As well as refering to the photos I took during dismantling as others have mentioned expensive items can drive assembly order. I bought a spare set of wheel hubs so I could use the old wheels and tyres for stability & to enable me to move the bike around when needed.

I made notes on areas such as wiring loom and what connections needed to be cleaned/restored. Likewise I kept an assembly log containing what had been torqued up and what need a final tightening to make getting all the bolts in place e.g. the engine mounts. I spent a lot of time looking for parts, in my second rebuild I used a spread sheet with numbered or lettered parts boxes. This would tell me if the part was elsewhere such as on my bike ramp or sent out for specialist restoration like the clocks, or for powder coating.

Hope this helps, the best way is the way you are comfortable with rather than anothers dictat, just worth knowing different approaches.

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