SOHC.co.uk Forums > CB500/550

CB550 First Build - Hondvarna?

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cinqmars2:
Oddjob, thank you so much, there are surely enough tips and tricks in there to keep me in check!

Rozabikes Tim:
Thanks.

Have been doing my 400/4 carbs with ultrasonic cleaner / standard solution.  Very good but could be better - may try your concoctiion in the ultrasonic cleaner.

Ta for the info.

cinqmars2:
Quick update, I dismantled the only straight pair of forks last night, the oil was well and truly spent, but all parts look to be in great condition inside. The lowers are chipped up, some are too deep to even bother sanding down so I think a good paint job would be the best approach for them. I cleaned out all the oil I could by rinsing everything in the shower, this expelled a lot of debris with rapidly flew down the plug so i never got the chance to actually see what it was. I don't know if was metal, plastic or just gunked up oil? There is no notable wear and all parts were present and correct according to my manual so I don't think it's cause for too much concern. The tubes were the main thing I was after from the forks as they are totally straight, but they do have a lot of pitting, some showing corrosion inside the travel margin so these will need a grind + re-chroming at some point. Expensive, but I think it will be worthwhile for a smart. new-looking pair of forks. I reassembled them with my original, polished lowers to keep everything together.

cinqmars2:
So a little bit of progress, we've had a new arrival at the studio! A lovely 18v impact driver, which means I've been able to get inside the engines. I promptly shattered two bits with it fighting with those ridiculous philips bolts, what a strange decision for Honda to make, bolts which undergo pretty extreme tightening, accesible only with screwdrivers? Makes no sense to me. I'll definitely be replacing these with stainless allen bolts. After some slicing of the screw heads I managed to get the most stubborn ones out. Dismantled the alternator, points, clutch and oil pump before I split the case. I've only been working on Engine 02 (the trashiest looking one) so far. Actually looks pretty straight once inside. What am I looking out for mainly here? Wear in the journals? How do I know if they're too worn? There was some crud in the oil pan, but nothing compared to some of the projects I've seen online, filter was dead clean surprisingly.

Clutch apart:


Lower:


Upper:

Bryanj:
Only safe way to judge bearing wear is plastigauge, but from what i can see of the shells they look OK.

If you can put up some closer pictures we can give you a better idea---DO NOT remove from cases unless you can bag them so they go back in the same place as there is no marking on an old shell to tell you the size

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