My Honda CB550 Bike Restoration Project

I've gotten most everything south of the engine off the rear of the bike and have bought a new tire (yep, gonna need one more, thanks) for it. I need to figure out how to make a stand, or chop and stack 4x4s to hold the beastie steady while removing the front end/wheel/brakes etc.

How embarassing. I realize that it's been months, months & months, since I've made progress. Damn speedo gear encroachment on the spark plug. Going to spray some more crud loosener on it. I've moved the bike a couple of times and it's now aimed out the garage, instead of sideways.

Will old brake fluid eat through plastic containers - or can I just drain it into an old plastic detergent jug?

I really must make more progress on this thing.:mad:
 
How embarassing. I realize that it's been months, months & months, since I've made progress. Damn speedo gear encroachment on the spark plug. Going to spray some more crud loosener on it. I've moved the bike a couple of times and it's now aimed out the garage, instead of sideways.

Will old brake fluid eat through plastic containers - or can I just drain it into an old plastic detergent jug?

I really must make more progress on this thing.:mad:

Brake fluid is corrosive and will eat through some kinds of plastics. Obviously not all, as it is sold and stored in plastic bottles. I just soda bottles for draining and transport to disposal sites.
 
My First CB550 Project

My First CB550 Project

I just bought a '78 CB550 Four-K in pretty good condition. Very good condition, actually. It had a stupid looking windjammer on in. So, I took that off, gave it a deep scrub and now it shines. The only thing I need is a headlight. I found someone in my area who may have a headlight for a 650.

Does anyone know if a headlight for a 650 fit a 550?

n516052131_2097734_366929.jpg


I'm pretty new to motorcycles in general. This is my first bike.

Also, I'd like to get some original exhausts someday. I didn't mind when I first bought it, but the more I am getting into it, the more I want all orginal sheeit.
 
Very, very, VERY nice looker there, even though it's 'eyeless'.

Here's a link for the service manuals that you can download.

http://hondatech.info/downloads/Moto/CB/CB500-550/

Didn't see a CB650 version. Get the part number for the bucket and maybe a Honda dealer can check the information on their system (or microfiche).
 
Should I buy a 550?

Should I buy a 550?

I owned a 750 back in the day and now I have the urge again. I know of a 550 for sale that is in good shape. Is this a great bike to ride like my 750 was? Is owning an old bike going to break my bank?

Thanks for your help.
 
Makes me want a bike but my parents would throw a hissy fit if I actually came home with one... :(
 
^You need to tell them about the real dangers of riding and the ways to avoid them- try to hide it and that is exactly what they'll be expecting, and you'll never ride (from experience here; took me over a year be allowed to ride, started when I was 16). Be honest, but find some safety data and research riding techniques (sorry that I'm not linking, but google should have some information) and most importantly RIDE DEFENSIVELY. Go all out on a curvy empty road or a track for all anyone cares, but in the city and motorway, be James May. Keep it slow, keep the revs low, always indicate, never go above of below the limit, shift slowly, etc. This might be tedious but it becomes second nature and is one of the most important things about becoming a rider.

Right, now it gets a bit more fun: Corners are of course leaned into rather than turned into, and once you've built up experience and confidence with your particular bike you can take corners twice as fast as cars.
About selecting a bike: There are a few basic styles- sports ("crotch rocket", usually reserved for hooligan bikers/ rich street kids :p) ,cruiser (Harley-Davidson style, big, bulky, and plenty of power), standard ("naked", what I've ridden for a while; my Yami is a standard-style) and vintage, old-style bikes of different sorts. There are several other categories (dirt, dual, trail, historic, etc) but they aren't very relevant as first bikes.

My suggestion is to go with a standard, something Japanese or German from the 80's or 90's. Yamaha, Honda and BMW are brands to watch for. They are often simple and reliable and go for damn cheap, even cheaper at scrapyards (often needing only minor repairs). If you're mechanically minded you can restore a bike fairly quickly, or fix a mostly-good bike even quicker. I reassembled what amounts to the entire front of my bike in an afternoon, so it isn't complex or difficult. Adding different mirrors, gauges, and/or stereo is easy as well.

Yes, I typed a huge post.

From your friendly Miata, motorcycle and manual-transmission advocate....
 
Does anyone know if a headlight for a 650 fit a 550?

If it's a three-prong wire then it should fit. Otherwise, check the wiring diagram for a 650 vs. a 550 - it's usually 3 wires blue, green, and white that are even used today, so it's probably not a problem. Get some adjustable headlight ears from CycleX for $15 (their site is a pain to navigate, however) and away you go.

I owned a 750 back in the day and now I have the urge again. I know of a 550 for sale that is in good shape. Is this a great bike to ride like my 750 was? Is owning an old bike going to break my bank?

Thanks for your help.

Shouldn't be too much of a problem unless you're tearing it apart for a full-on restoration - Honda engines are known to tick past 100,000 miles and there are plenty of resources for SOHC owners to upgrade to modern parts (dual front disc conversions, steel braided brake lines, Dyna ignition, carb upgrades, to name just a few). They're cheap to own and cheap to run, and a few upgrades like those can go a long way.
 
Last edited:
Makes me want a bike but my parents would throw a hissy fit if I actually came home with one... :(
Dude, you're 24 and you still care about your parents throwing hissy fits?? :p Heh heh.

I'm 24 as well, my mom was also sternly against me having a bike. With all due respect and love, I didn't care what she thought of it and went out and bought one anyway. It's been over a year now and she's fine with me riding bikes now, mostly due to the mature way I've been going about it. (ie, no wheelies, stoppies, race tracks, stunting, etc.)

So if you want one I say go for it. Just get something small at first and prove to your parents that you're not getting one so you can go stunting and doing generally stupid stuff.
 
Figured I owe you guys an update on what's going on.

So far I've installed my new front and rear sprockets and a new chain. And right now I'm in the middle of painting my bodywork, starting with my front and rear fenders.

I heard about the $50 Rustoleum paint job that I threatened to do here, and now I've actually gotten around to it. I've spent too much money on this bike already and this seems like a more hands-on and "creative" way to repaint my bike.

So without further ado...


https://pic.armedcats.net/b/bl/blaro/2009/05/30/stripping_paint_off_fenders.JPG

Here they are as I was stripping the original coat of nasty flat black rattlecan paint.


https://pic.armedcats.net/b/bl/blaro/2009/05/30/before_paint.jpg

Wet sanded the bare metal with 600 grit, smooth as a baby's bottom.


267211_front200.jpg


I started with a can of Rustoleum Protective Enamel in Regal Red, then thinned this with mineral spirits. Approx. 50/40 Rustoleum and mineral spirits. The consistency I'm aiming for is "like milk."


https://pic.armedcats.net/b/bl/blaro/2009/05/30/first_coat2.JPG

I may have added too little thinner, however, as the coat I put on the parts was rather thick.


https://pic.armedcats.net/b/bl/blaro/2009/05/30/first_coat1.JPG

It runs a little, but I'm not too concerned as it's the first coat and I'm sanding it anyway.


https://pic.armedcats.net/b/bl/blaro/2009/06/02/wetsand2coats_2.jpg

Two coats later, I've wet sanded with 600 grit and also took the time to hammer out some minor dents.


https://pic.armedcats.net/b/bl/blaro/2009/06/02/wetsand2coats_1.jpg

The runs were noticeable until I put my 3rd coat on this afternoon. Going to put a 4th on tomorrow, while waiting at least 12 hours in between.
 
What I've been up to lately. It's starting to look like a real motorcycle:

-finished installing the rear wheel
-installed rear shocks
-installed the chainguard, and fiddled with some clearance issues with the massive Progressive shocks
-new chain and sprockets
-powdercoated the regulator panel, rebuilt, and installed
-reinstalled carburetors. Realized that i bought the wrong-size bands for the rubber carb boots and had to buy 8 more...

https://pic.armedcats.net/b/bl/blaro/2009/07/05/IMG_2646.jpg
https://pic.armedcats.net/b/bl/blaro/2009/07/05/IMG_2647.jpg
https://pic.armedcats.net/b/bl/blaro/2009/07/05/IMG_2648.jpg
https://pic.armedcats.net/b/bl/blaro/2009/07/05/IMG_2649.jpg
https://pic.armedcats.net/b/bl/blaro/2009/07/05/IMG_2650.jpg
https://pic.armedcats.net/b/bl/blaro/2009/07/05/IMG_2651.jpg

And the results of my handiwork today: I had tried some paint stripper on half the tank but it didn't do too much. So I ended up sanding the entire coat of ratty flat black paint off. I got to the primer in some places, and bare metal in others.

https://pic.armedcats.net/b/bl/blaro/2009/07/17/before_sanding.jpg

https://pic.armedcats.net/b/bl/blaro/2009/07/17/after_sanding_(2).jpg

https://pic.armedcats.net/b/bl/blaro/2009/07/17/after_sanding_(1).jpg

That's a lot of bondo. :eek:

https://pic.armedcats.net/b/bl/blaro/2009/07/17/bondo_detail.jpg

Took about 3 hours of sanding, first 60 grit to remove the paint, then 100 and 220 grits to smooth it out a little. (I swear, I could hear the blisters forming. :shock2:) I'll be getting the filler area sandblasted and maybe the underside.
 
Last edited:
Dude, you're 24 and you still care about your parents throwing hissy fits?? :p Heh heh.

I'm 24 as well, my mom was also sternly against me having a bike. With all due respect and love, I didn't care what she thought of it and went out and bought one anyway. It's been over a year now and she's fine with me riding bikes now, mostly due to the mature way I've been going about it. (ie, no wheelies, stoppies, race tracks, stunting, etc.)

So if you want one I say go for it. Just get something small at first and prove to your parents that you're not getting one so you can go stunting and doing generally stupid stuff.

I live at home. :tease:
 
I just read the whole thread back to front, and I can only say huge respect to you BlaRo! :thumbup:
I'd love to do something like this myself some day...


I live at home. :tease:
Pfft, so do I. And did my mum freaking out every time I mentioned I'd like to do the motorcycle licence stop me? Hell no! Yeah, she was upset when I started, but she came to terms with it rather quickly.
And that's what I've heard from pretty much everyone in such a situation: parents will simply accept and learn to live with it, most often sooner than you'd might think.
So just grow some balls and go ahead! Wait, uhm... :blink: Well, you know what I mean. :p
 
Wow it's really coming together now! Hard to believe it was all just a pile of rusty parts not long ago. Keep up the good work and I'm sure I'm not alone in wanting to see the shiny finished product.
 
Threw on the air cleaner and filter box today, along with the front forks and front wheel. Then I realized that I had forgotten to install the fuel tubes onto my carburetors - :bangin: - so I removed the battery box, electrics panel, air cleaner, filter, and various loose hoses, and got my carburetors off the engine in 10 minutes flat. Which I hope is some sort of a record.

Finally got around to rebuilding my petcock too after having the kit lying around for two and a half years. And the tank is being sandblasted and should get back to me within the week.

Pictures to come soon.
 
This restoration is a lot more thorough than I thought it was going to be. Credit for giving it the effort it deserves. It's looking good already and you're going to enjoy riding it even more when it's finished because of all this work. And, you'll know the bike inside out afterwards - if anything happens to go wrong in the future you'll have it fixed in a jiffy.

Yay Blaro.
 
Only a few hours worth of work to go, man - keep going!
 
Well, im very impressed with your restoration of this wonderful looking bike...

to be honest, the only reason i found this forum is becasue i recently aquired a 1976 honda cb550 lol, for free lol. and i thought to myself, i want to restore it. you have shown me its possible! im afraid tho mine needs alot of work :p

here is a pic
76cb550.jpg


lol i know i have alot of work cut out for me... but i think everyone needs to restore something atleast once in their life lol
 
Top