My Honda CB550 Bike Restoration Project

[BigDaveDogg]

Sweet project. A buddy of mine took on a similar project, but unfortunately it was just disassembled and that's likely where it'll sit forever. :lol: Nice bike, and you reminded me I need to send my passenger footpegs for powdercoating.

 

[TC]

I'd like to do a similar project with an old dirtbike. Any suggestions?

 

[tigger]

I'd like to do a similar project with an old dirtbike. Any suggestions?

Want to buy a Yamaha?

I think just about anything old, carbureted and air cooled is a good first project. I'm just about to tear into my bike, and it doesn't look like it will be too bad.

Props to you Blaro, I'm not sure I've got the nads to rebuild and re-tune 4 carbs at once. Do you have any other plans for break? On the bike I mean, not Bioshock? :lol:

 

[BlaRo]

Thanks! The carbs were surprisingly easy to work on and I'm glad I'm done with those. Of course, if they were easy it must mean I did something wrong, which I'll find out about when I finish the bike...

Props to you Blaro, I'm not sure I've got the nads to rebuild and re-tune 4 carbs at once. Do you have any other plans for break? On the bike I mean, not Bioshock? :lol:

Well, I'm on the last level and I'm about to kill Frank Fontaine so I'd say that part of my life is almost complete. Other plans for the bike include turning in my fork bottoms to be cleaned and powdercoated and rebuilding the entire front fork when I get them back. While that happens I'll be taking apart the master cylinder somehow and replacing all the parts. No idea how to start though, any suggestions/websites?

Shouldn't be too bad to get those out of the way before I go back to school. After all...how hard can it be? :lol:

 

[klutch]

Damn fine progress. I'm at about the same stage...frame is pretty much stripped of the oem paint, and I'm finishing up painting the engine. Its fuel injected, so a little more complicated, but doesn't have to be completely stripped down (thank god...). Waiting on a couple of parts so I can have the frame and some misc. bits powdercoated. By the way - did your exhaust get coated with high-temp powder? The baking process is only around 400 degrees; I know the CB's didn't run too hot, but the headers can really cook, and any coating not meant to withstand that heat will bubble and peel.

If you're going about painting and want to keep it cheap, I'd recommend DupliColor's high heat engine enamel - and the ultra high-heat with ceramic components for anything exhaust related. The standard high heat also has a clear-coat, so its great for painting engine bits. If you're looking for OEM parts as well, check out www.mrcycles.com, they're much cheaper than going to the stealership for pretty much anything.

 

[BlaRo]

Master cylinder fun, as promised/alluded to.

https://pic.armedcats.net/2008/01/04/leverdisconnectedfrommastercylinder.JPG

https://pic.armedcats.net/2008/01/04/rubbertiponendoflever.JPG

Both levers came with this dorky rubber tip which was encrusted on and rather disgusting.

https://pic.armedcats.net/2008/01/04/rubbertipremoved.JPG

Looks much better after removing and washing (I didn't take a picture of the latter).

https://pic.armedcats.net/2008/01/04/topofmastercylinder.JPG

First step was to remove the rubber seal that was blocking the piston and its infamous circlip from access.

https://pic.armedcats.net/2008/01/04/aftermath.JPG

Well, that went smoothly.

https://pic.armedcats.net/2008/01/04/rubbersealremoved.JPG

Luckily, I have replacement parts:

https://pic.armedcats.net/2008/01/04/mastercylinderrebuildkit.JPG

https://pic.armedcats.net/2008/01/04/pistonwithoutrubberseal.JPG

Ewww.

More to come later!

By the way - did your exhaust get coated with high-temp powder? The baking process is only around 400 degrees; I know the CB's didn't run too hot, but the headers can really cook, and any coating not meant to withstand that heat will bubble and peel.

Didn't ask - I'll be sure to when I go pick up some more parts that I've sent in for powdercoating. Top and bottom fork trees and the battery box.

I've been getting my OEM parts from the aptly-named Honda Parts Direct which alongside eBay is pretty good on prices even though their shipping costs are awful.

 

[tigger]

If you're looking for OEM parts as well, check out www.mrcycles.com, they're much cheaper than going to the stealership for pretty much anything.

Bookmarked .

Shouldn't be too bad to get those out of the way before I go back to school. After all...how hard can it be? :lol:

Heh, that's what I keep telling myself. I think I'm going to start tearing my bike down this week. Looks like that master cylinder rebuild went well, but what do you have against Frank Fontaine? :lol:

 

[BlaRo]

Heh, that's what I keep telling myself. I think I'm going to start tearing my bike down this week. Looks like that master cylinder rebuild went well, but what do you have against Frank Fontaine? :lol:

His accent.

I sent some parts to be powdercoated last week, my triple tree, a battery box, and my forks. I got a quote for $150 for all of them, but when I got back I realized that my fork tubes were in good shape and that I could save my birthday money for something better (like going to see Blue Man Group in Boston with a girl who would later stand me up ), and that I could do the work myself. So I did, driving back and picking up those forks and 320 and 600 grit sandpaper from Home Depot. And after a few very sore fingers, here are the results:

https://pic.armedcats.net/2008/01/08/DSC02169.JPG

Old one on left, new one on right, I hope you didn't need me to tell you that.

https://pic.armedcats.net/2008/01/08/DSC02171.JPG

https://pic.armedcats.net/2008/01/08/DSC02172.JPG

Hell of a difference:

https://pic.armedcats.net/2008/01/08/DSC02173.JPG

https://pic.armedcats.net/2008/01/08/DSC02174.JPG

I didn't stop there, though - took care of my crusty drum brakes:

https://pic.armedcats.net/2008/01/08/DSC02175.JPG

https://pic.armedcats.net/2008/01/08/DSC02180.JPG

What's left to do: buff everything out with #0000 fine steel wool and apply clearcoat. And get my parts back from the shop, of course.

 

[klutch]

Hey, if you want to bastardize it into a cafe racer, I hear the R6 conventional forks fit without much trouble...

CB550's make great looking cafe bikes.

 

[Viper007Bond]

Hey, if you want to bastardize it into a cafe racer, I hear the R6 conventional forks fit without much trouble...

CB550's make great looking cafe bikes.

Fuck that looks badass. Low riding cafe bikes look so damn awesome.

 

[BlaRo]

Cafe bikes FTW (when did "bastardization" become a bad word? ). These are a few bikes that inspired me:

https://pic.armedcats.net/2008/01/14/10.jpg
https://pic.armedcats.net/2008/01/14/16.jpg
https://pic.armedcats.net/2008/01/14/20.jpg

And klutch: those headers were ceramic coated.

 

[BlaRo]

Some more work before I went back to school:

They were right, it can't be done. That damn circlip inside my master cylinder snapped one of my Stanley screwdrivers in half. So I'm throwing it out the window and retrieving it when I come back so I can take it to a shop. Let them deal with it, I'll have money by then.

Meanwhile, I've hit up the junkyard. Believe me, every gearhead worth his salt should go to one on a regular basis. Even a mundane one is like the greatest carnival ever; $2 brings some of the most easily amusing fun all afternoon. What a deal!

https://pic.armedcats.net/2008/01/15/DSC02187.JPG

I was able to salvage a pair of Progressive Suspension 12 Series shocks in pristine condition from a newly-wrecked 1980 Honda CB750 Custom. Ended up paying $40 bucks for the pair when a similar set (shocks + springs) would have been $200+ dollars. It seemed fishy but they were mint, so I'm keeping these (or at least taking them to an expert for some advice).

https://pic.armedcats.net/2008/01/15/progressive12series.jpg


Picked up a set of equally mint badges from the same bike:

https://pic.armedcats.net/2008/01/15/DSC02189.JPG


Of course, I couldn't help wandering around, and between smashed Integras and burned out Mazda3s I stumbled across that veritable unicorn of the junkyard searcher, a 1988 French Turbo Wagon.

https://pic.armedcats.net/2008/01/15/DSC02177.JPG



Later I found some more cars in the European section that truly broke my heart, including a 1988 BMW 633CSi, black with red seats, that I recognized from sitting near my workplace for a year. It had been for sale for $3500 and I had actually, seriously considered buying it and rebuilding the engine for my senior project because of my of E24s. Shame it had to end cylinder-headless and humiliated in a field of wreckage.

And something that will surely break the hearts of the many Jaguarphiles here: a beige Series III XJ6 Vanden Plas was parked right behind it, with a lovely cream-colored interior that was still in good condition. I sat in it and breathed 30-year old wood and ugly Massachusetts snow. The front badges were already gone, but I took the Vanden Plas badge. I know, I'm a cruel bastard, I'm sorry. Don't be too mad at me, Spectre.

https://pic.armedcats.net/2008/01/15/DSC02176.JPG

I felt 36.4% classier just looking at it.

https://pic.armedcats.net/2008/01/15/DSC02186.JPG

Polished my carburetor tops and float bowls while I was at it.

https://pic.armedcats.net/2008/01/15/DSC02192.JPG

And here are my finished forks.

 

[KaJuN]

Put the Vanden Plas badge on the bike. You know you want to. 8) Great deal on those shocks too! I'll have to hit up the local scrapheap sometime to see if I can find anything interesting.

Those bastardized cafe racers look really, really nice. Now you have me partly considering doing something like that to my own bike.

 

[hansvonaxion]

Cafe bikes FTW (when did "bastardization" become a bad word? ). These are a few bikes that inspired me:

https://pic.armedcats.net/2008/01/14/16.jpg

Love em.
This one looks pretty much like my old CB350/4.

 

[tigger]

Thanks to this thread, I'm considering going out to the shop right now and tearing into my Yamaha :lol:. Any other night I would, except it's currently 15 degrees (and falling fast) and I've got no heat in the shop.

Great work cleaning that stuff up BlaRo, I'm not sure if I'll go that far with mine, at least not at first.

 

[KaJuN]

Cafe bikes FTW (when did "bastardization" become a bad word? ). These are a few bikes that inspired me:

I just noticed this bike has the same tires as mine. Sweet! I really like this bike except for the exhaust. It looks weird having a modern exhaust when everything else looks retro.

 

[brockster]

Here's another inspirational CB550 resurrection!

Here's another inspirational CB550 resurrection!

Thanks to this thread, I'm considering going out to the shop right now and tearing into my Yamaha :lol:. Any other night I would, except it's currently 15 degrees (and falling fast) and I've got no heat in the shop.

Great work cleaning that stuff up BlaRo, I'm not sure if I'll go that far with mine, at least not at first.

Yup - got inspired last night also, though my garage is unheated.

When I plug in my electric radiator in the garage, it kills the breaker if I have the lights and stereo on also. Which also then kills the sump pump. Not good. Found some cheap insulated coveralls at the thrift store and those work pretty good.

Yeah, I started cleaning a bit on my CB550 last night. Tried the Coca-Cola and aluminum foil rub on the rusted spots on the chrome of the exhaust. But with the coke and the dirt, it turned it dull gray. Bleh.

Mine stilll seems to be in better shape than this resurrection. It had been sitting outside for 10 years and was locked up. Another cool story.

 

[BlaRo]

^ Sorry mate, you can't come here and expect to be welcomed with a post like that without posting pics of your bike.

Mine stilll seems to be in better shape than this resurrection. It had been sitting outside for 10 years and was locked up. Another cool story.

I can't find saddlebags for the CB550, so I might have to nick his ammo crate idea...

Also, I have a feeling that duct tape will be inevitable sometime later in life. I'm just thankful my fork tubes don't look like his!

 

[KaJuN]

Yeah, I started cleaning a bit on my CB550 last night. Tried the Coca-Cola and aluminum foil rub on the rusted spots on the chrome of the exhaust. But with the coke and the dirt, it turned it dull gray. Bleh.

If it's just pitting you're trying to get rid of try some SOS pads and water. It worked beautifully on my Yamaha.

And a big from just up the road a bit.

 

[brockster]

I wasn't just BSing. Pics? You want pics? Here you go.

On the way home in my Astro. The four tie-downs aren't visible.

Provenance - (Yeah, I've been watching too much Antiques Roadshow...)

Hippie King-Queen seat. Dig dat funky stitching!

Gen-u-whine Lester Mag wheels. IMHO, much preferable to spokes.

Note in the third shot, right above the sidecover, there is a hole in the vinyl. Any ideas on how to repair that? Take it to an upholstery shop, or is there something that I can do to make it look right?