Project CB690 (KTM 690 engine in a CB550f frame)

[goodoltup]

if you want an even "brushed" finish ive had good luck using one of these belt adaptors for an angle grinder with a scotch bright belt. It wraps around the tube and leaves a really nice finish. looks factory.

http://[URL]https://www.ebay.com/it...8UuLyxDPmbASxhIjT9Vp647pRSM=|tkp:BFBM2JKpxbRl

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http://[URL]https://www.ebay.com/it...xCfben7gYFAZ8L6T4DKlvnYg==|tkp:Bk9SR_aN0MW0ZQ

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Hi Doc, thank you, good tip! That's something I'd be very interested in investing in.

 

[goodoltup]

Some great progress man, I like the finish on the exhaust. Did you make the Fender Stays?

Cheers! I did make the fender stays. I rolled 6mm steel and brazed some bosses on. More on Page 14.

 

[goodoltup]

Why doesn't the neutral light work? Let's spend 2 hours hunting it down. I checked the function of the gear position switch. I poured over the wiring diagrams. I checked the continuity from the connector to the EFI computer and the instrument display. I checked that I hadn't incorrectly reassembled the connector and misplaced the wires. Oops. I had swapped the neutral switch connector with the throttle position sensor connector. They are the same 3-pin connector and are very close to each other. Problem solved.
I was never completely happy with the wiring harness I made, some of the spurs didn't end up coming out of the harness in the right location or the spurs were too long. Now that I've got it partially un-taped I can correct that, so silver lining there.

 

[goodoltup]

I took the opportunity to replace a bunch of connectors with automotive style sealed connectors. Specifically Sumitomo HM090 and MT090. I love them.

 

[goodoltup]

Harness is all done now, and better than it was before.
Very few things to do now. Chainguard, headlight shell tidy up, fluids and a test run.
Then, of course, the paint. That comes last.

 

[doc_rot]

its looking great. cant wait to see the paint.

 

[Rider52]

Something bright I hope!

 

[goodoltup]

Something bright I hope!

Hey I'm really struggling to pick out a paint scheme, what do you think? You think it needs something bright to balance out the black frame and wheels and stuff? I was thinking one solid colour, but can't really choose one.

 

[ridesolo]

Seems like the various manufacturers have a favorite signature colors; red for Honda, blue for Suzuki, yellow for Yamaha, isn't KTMs color orange? Maybe KTM orange in a Honda-like paint scheme?

 

[goodoltup]

Seems like the various manufacturers have a favorite signature colors; red for Honda, blue for Suzuki, yellow for Yamaha, isn't KTMs color orange? Maybe KTM orange in a Honda-like paint scheme?

I had thought of that! Maybe the CB550f orange colour? Or maybe KTM orange but in the two-colour CB350 scheme?

 

[goodoltup]

Chainguard is complete. It is a cut-up KTM part, with the original mount removed and replaced with aluminium, and a relief area for the shock. Also I extended it a bit in the front to get better chain coverage right next to the sprocket. I don't love it, but it disappears in the bike and looks fine.

 

[goodoltup]

Also finished the instrument pod. I finished sanding and prepping the epoxy filler and gave it some paint, also don't love it, but man I have to finish this bike. It looks fine.

 

[goodoltup]

Also replaced my 20 year old Craftsman 1/4 inch set with a new Wera set, highly recommend.

 

[ridesolo]

I had thought of that! Maybe the CB550f orange colour? Or maybe KTM orange but in the two-colour CB350 scheme?

That's the ticket, laddie!

 

[goodoltup_1]

Hey it's me! I can't login to the forum for some reason, I've emailed the admins and received no response. I've re-registered under goodoltup_1, and will post what I can until this is fixed.

 

[goodoltup_1]

I stripped the tank and sanded down to the base metal. The tank was much more pitted than I had remembered, especially under where the original decals went. After much work it smoothed out enough.

 

[goodoltup_1]

Polyester filler, sanding, guide coat, etc. I filled the tank badge hollows, but then sanded down too much. All in all this took several days of re-application and sanding.
By the way, I bought some really cheap cutting boards from amazon, they do a great job for mixing the body filler, and other epoxies and such.

 

[goodoltup_1]

Final body filler and sanding, then etch primer. I did about two coats of etch primer, then switched to high-build primer to help fill in the corrosion spots. Oh and the side covers, too, don't forget about them.

 

[goodoltup_1]

Still some worrying ghosting by the badges, but that will get sorted.

 

[goodoltup_1]

Color! It is Mazda 46V paint, Soul Red Crystal. It's a 3 stage paint, so it requires primer, base, pearl clear, and final clear.