CB550-4 cafe' build

TerryK

TerryK

"Lift up yer' kilt n' let it dangle!"
I am managing to make a bit of time in the evenings to work on a little project bike. I recently found a 1973 Honda CB550-4 and a spare rolling chassis. Got the both of them for $250 and they are destined to become one bike. I've always loved the old school cafe' racer look and the little sohc Honda's make great bikes so I'm doing a low budget build. Here's a few pictures.

This is roughly what I'm shooting for (just not high dollar like Benji's!):

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Just off the truck. The one with the engine is the 73' the other is a nice shape 75' roller which will be the basis of the project.

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The engine was seized because the dumbass who owned the bikes left the 73' outdoors for 2 years, minus any type of cover and also it's starter, so of course water entered the engine through the airbox, which rusted 3 cylinders and damaged the carbs. I managed to free the engine up once I pulled the head but once I honed all four holes it became obvious that it was in need of a bore job, which means new pistons and rings. At about $450.00 that is not in the budget.




Corrosion in the exhaust ports:

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1&2 combustion chambers and cylinders:

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This is as far as I have to tear the engine down. Pulled the oil pan and everything inside is perfect.

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Lots of parts! lol:

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I cleaned up valves and springs. They came out great. If the seats are ok in the head all it will need is a valve lap.

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Sooo, I just bought a low mileage cylinder and pistons/rings on eBay for $102.00 so I'm in business! With luck I can just clean everything up and bolt it all back together so I have a runner. Once it's running the frame mods, seat/cowl and gas tank will be next. I have the brake calipers apart and everything appears in great shape so all thats needed there is a good cleaning, some new brake lines and reassembly. I have a seat/cowl coming ($110.00) and one of those Bennelli fuel tanks ($120.00) and a new battery ($70.00). The chain and sprockets are good and the tires are decent. A bit of cleaning, some wiring, general detailing and some paint and I should have a cool little daily rider for around $1000.00!! I'll keep you posted on my (slow) progress.
 
Curious to see how you make out with this. For that price, even with the problems, you got a hell of a deal in this CB climate.

Around here, no title, non-running are going for $1200 sometimes! Ugh!!!
 
Well it looks like 2 of the 4 carbs are junk. Too much corrosion around the mains. Soooo, looking for a replacement set if anyone has one for a reasonable price. I also have a line on another 550 (free) if my friend, a bike shop owner still has it in his warehouse. I'll know this week.

Here's the cleaned up head, ready for re assembly. Valves lapped in nicely with minimal effort.

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Front calipers cleaned and repainted. Not perfection but thats the effect I'm going for. Clean but well ridden....like a motorcycle should be!!

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Badly rusted fork tubes under the headlight mount tubes. Anyone know of a nice minimailist replacement for the mount that would cover up this rust or do I have to fab up something?

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Here's the rolling chassis. I started stripping off all the unnecessary bracketry in preparation for under rear cowl electrics/battery mounting.

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An update (if anyone gives a shit! :P )

Here's the frame with all the under seat bracketry removed in preparation for under-cowl electrical/battery. Still have to weld up a frame loop once I decide what seat I'll be using. Rough mock up of rear sets as well.

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This was supposed to be a semi-rat bike....but I got carried away polishing up the covers. They were BADLY corroded and I forgot to take "before" shots.


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So I've had this old Honda speedometer for at least 20 years,waiting for a project bike. Here is a mock up of the dash with the restored idiot light housing. If I even use a tach it will be one of those tiny ones or a digital one, but I really like the single gauge look. I'll cut the bracket down to contour with the speedo. I think it looks bitchen!!

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Very nice score indeed. Wish I could find bargains like that over here ??? You seem to have it well sorted. Nice work on those covers, but yeah, you've done it now. No going back ;)


Should be a great bike when you're done.


cheers
ian
 
Keep up the good work man. I hate to see a bike neglected like the previous owner did. Great job on saving on her and keeping her out of the scrap yard!!!
 
Thanks guys. My goal was to have a cool bike roadworthy for under $1000.00. lol. I know it can be done because I got 3 550's for $250.00, bought some parts here and there and now I'm selling off parts I don't need and bartering other things. My cousin is going to do a tank with knee dents for me and I'm going to finish his garage trim. I could very well come out even here and have a cool cafe racer in my garage! Hey, I'm Scottish and Ukrainian so pinching a penny comes honestly to me!!

Question: How was copper wire invented?

Answer: Two Scotsmen fighting over a penny!
 
Update.

Got my new rust free forks (ebay) spent a ton of time sanding and polishing the lowers, then like Honda does, I clear coated them. They look great. My Roc City seat arrived but I haven't started to mount it yet. (still have to weld on a frame loop). Front wheel was cleaned up and bearings greased. Front rotor centers were painted gloss black as were the calipers. Brakes and wheel mounted ad ready to go.

After a thorough cleaning and a fresh coat of silver paint, the engine lower end was installed in the frame and bolted up with the cleaned up bolts. Top end has been de-carboned, honed, lapped, cleaned and painted, ready to be mated to the lower end. I have a decent set of carbs (finally!) on their way as well as some really nice forged aluminum headlight ears and a black faced mini tach from Parts n' More.

Anyone know a good source for simple LED tail/brake light setup? Round is what I'm looking for.


Final speedo mounting. I like it...but I decided to order a mini tach because, well I want a tach! Wish I had a tach to match this speedo because I would eliminate the speedo and mount the tach the same.

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New forks:
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Front wheel, forks and brakes done.

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Coming together finally.

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Cylinders, head and valve cover painted/polished and ready for install.

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Mag cover resto. The actual cover is the last part to be cleaned and polished on the engine. (still working on it)

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Late night session. :P

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I love these 550's, you're making good progress on it. My engine wasn't nearly as 'worked' as yours; and it alone was good enough work. I could only imagine what you've done to get to this stage. keep it goin!
 
That engine is looking SO good. Great job. One day, I will get around to getting mine out of the frame and going to town on it like this. I can only hope it comes out looking as sweet as yours.
 
Thanks a "ton" guys! :P

Thing is, this is a budget build so I haven't really spent any money on the engine, just hours decarboning and cleaning the internals and MANY more cleaning and restoring the outside. It's basically all elbow grease and masking tape! lol

Anyhoo, I made a simple chain guard from aluminim flat bar. Came out nice. And my seat came in! Woot!! This thing is nice!

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yeah you got a great deal on the stacks! some pod filters go for 30 each, and you got all 4 fer 37, makes a great deal!
 
Hey! Just so you know there is a 555cc big bore kit originally designed to go in the 500cc floating around for about $150. Brand new pistons and rings made by MC (the original piston manufacturer for these bikes). It works out to be about a 3rd over (it's late for me and has been a long day so forgive me if I'm off on this) for the 550 and since you are going to have to bore it anyway... cutting an extra little bit off the wall is no big deal. I did this and was super excited about it. You cant even buy rings for the amount you get this kit for.


Here is a link to check em out: Click Me


Also, Looks like you're off to a really great start! We have similar stories except you started of in MUCH better shape than I did. Lucky you. Good luck!
 
sxecafe said:
Hey! Just so you know there is a 555cc big bore kit originally designed to go in the 500cc floating around for about $150. Brand new pistons and rings made by MC (the original piston manufacturer for these bikes). It works out to be about a 3rd over (it's late for me and has been a long day so forgive me if I'm off on this) for the 550 and since you are going to have to bore it anyway... cutting an extra little bit off the wall is no big deal. I did this and was super excited about it. You cant even buy rings for the amount you get this kit for.


Here is a link to check em out: Click Me


Also, Looks like you're off to a really great start! We have similar stories except you started of in MUCH better shape than I did. Lucky you. Good luck!
Click to expand...

That is a great deal for sure, but if you had read the entire thread you would have seen that I bought a block and matching pistons to replace the seized ones.
 
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My technical director checking my work.

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Getting excited now to have this lump back in one piece! :P

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