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post #1 of 46 (permalink) Old 03-23-2011, 04:12 PM Thread Starter
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CB550 Cafe Build

Hello,

New to the forum and thought I would show-off (modestly) a bit of what I've been up to.

About me:
I grew up on dirt bikes, but have never owned a street bike before. I have done a lot of car modifying for auto-X and drag racing, so I hope some of that transfers!

About the bike:
I bought this 1976 CB550F in October last year as a 'winter project'. Being new to Chicago (from Arizona)... I didn't realize quite how cold unheated garages are... and the project quickly moved to a Spring one!
Bike was purchased non-running & I had no idea what to look for. It was dumb luck it is as solid as it is, and even so - its pretty rough!

I finally got started on it last weekend & have made a little progress.

Woohoo - hit 15 posts - here are progress pics!

Bike as it came to me:


And a few more cell pics showing other angles and the sad condition:








In the 1st day of wrenching I tackled the most offensive pieces &
Removed Sissy bar
Removed rear fender
Removed rear brake & turn lights
Installed new rear shocks (with reservoirs) from a CB1100F (thanks Ebay)

I also turned the bars down to get an idea of whether I could chop the existing ape bars to save a few bucks... but I could not!



Second day of wrenching was also pretty effective.
Got the rear 16" 'cruiser' wheel switched out for a 18" 'cafe' style one
Removed the very rusty tank
Removed the rack of carbs & started clean up



Most recent day of wrenching happened on a weekday.. and was cut short by work. Still knocked out a few items:
Finished Carb rebuild & reinstalled Rack & linkage
Installed less rusty tank from a 550K



And thats where I'm at for now.

If everything goes well in the next couple days, I am going to throw some gas in the tank, and get a battery and try to start it.

If it starts, I'll start the actual rebuild, and start pulling things apart, cleaning, fabricating, and generally making things more pretty.

If it doesn't start... Then its the not-so fun task of troubleshooting...

I'll try and get a better profile shot

Last edited by BrianK; 03-25-2011 at 02:42 PM.
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post #2 of 46 (permalink) Old 03-23-2011, 04:14 PM
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post #3 of 46 (permalink) Old 03-23-2011, 04:15 PM Thread Starter
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Thanks!
It's pretty rough... but it'll get there!

I'd purchased some new parts to create a more modern interpretation of a cafe (USD forks from a 03 GSXR 750, clip-ons, 6 Piston Tokico calipers, dual 320mm rotors) but like most projects... am running into funding issues and may take a more 'period correct' approach since I can do that for a bit less money.

We'll see!

I'll upload some pictures of how I would like to see it finished once I can post outside URL's.

Last edited by BrianK; 03-23-2011 at 04:52 PM.
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post #4 of 46 (permalink) Old 03-23-2011, 04:20 PM
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Thanks!
This is pretty rough... but it'll get there!
Any project done well takes time.

What kind of autocross stuff did you work on before this?

Have you taken an MSF course for street riding yet?

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post #5 of 46 (permalink) Old 03-23-2011, 04:33 PM Thread Starter
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No MSF course yet - Signed up the ECC one in September, but I HIGHLY doubt the bike will be finished before that!

I auto-X'd a couple cars. I had an 1986 SVO Mustang that carved some cones pretty well (better than me!), then an SE-R Sentra (B15 style), and lastly a 6-Speed Accord that turned really me onto Imports. The 'project' car during most of that was a 94 Z/28 that started stock, and ended as a pretty solid middle ground between handling & Drag.

In all the cars I took pride in doing the work myself so that I could learn how & so that I could afford it! My time is cheap, the shops isn't!

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post #6 of 46 (permalink) Old 03-23-2011, 08:40 PM
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Sounds good I will be following this thread!
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post #7 of 46 (permalink) Old 03-24-2011, 07:06 AM
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Just to name a few.

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post #8 of 46 (permalink) Old 03-24-2011, 09:52 PM Thread Starter
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^^ Thanks - I'm sure I'll be bugging some of them!

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post #9 of 46 (permalink) Old 03-24-2011, 10:12 PM Thread Starter
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Alright!
15 posts, pics added in!

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post #10 of 46 (permalink) Old 03-25-2011, 01:06 PM
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Looks good, take your time, it's not a race, atleast that's what I'm learning from my winter project haha. The key is to keep making steady progress

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post #11 of 46 (permalink) Old 03-25-2011, 02:40 PM
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The most fun thing about old bikes is fixing the same thing several times.

Welcome. I dig me some old bikes.
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post #12 of 46 (permalink) Old 03-25-2011, 02:57 PM Thread Starter
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No progress pics from last night (stupid brake fluid soaked hands... I'll add some relevant ones in soon) but I finally managed to revive my front brake.

Caliper was seized and the lines were dry, but a friend and I pulled them apart, 'un-stuck' the caliper, ground away all the rust on the piston and pad, then put it all back together.

The brake works as it should (piston pushes & retracts) and so far it is holding pressure and fluid. We'll see how long I decided to use that... but at least it functions.

Throttle cables are no good though. The HUGE return spring on the carb rack is still not enough to close the throttle. I need to twist the grip backwards to close it. I'll start it like that, but am not going to ride it!

Pulling apart the throttle tube it looks like the tube itself is broken and that may be causing the bind. I'll order a new one and hope for the best, but I think new cables are in my future to.

Last update - I got a battery!
So this weekend I get to see if it starts...
I'll either be posting very happily, or very drunk...

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post #13 of 46 (permalink) Old 03-27-2011, 12:43 AM Thread Starter
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Here are those pictures I promised.

Front calipers/lines after reviving them (still need cosmetic help - but at least they work!)


^^ I can't imagine the 2 sides of the clamp should be discoloring at different rates... but we'll see how they clean up.

Newest side profile - still trying to decide whether to go clubmans (for authenticity) - Superbike bars for comfort - or clipons....


And the view from the back


These last pics are what I had originally planned to use - but I am starting to think a more 'classic' approach is the right way to go.
Thoughts?



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post #14 of 46 (permalink) Old 03-27-2011, 06:03 PM
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For me and based on my experienced, ill make the bike rideable first and when that is done i slowly buy the cool parts or else it'll just end up stuck inside the garage. Ive done that with my other projects and it took to long to finish it because i bought all the cool parts. lol But money is no problem then no need to worry.

Keep up the good work.
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post #15 of 46 (permalink) Old 03-27-2011, 07:17 PM

 
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If the new stuff is with in an inch or so from bottom clamp to axle from the old stuff Mount it up .
You may need to find and fit custom bearings for the neck.Although very technical not that much time machining a little more on design.

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I'd love to help but I don't chase parts.
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post #16 of 46 (permalink) Old 03-27-2011, 07:18 PM

 
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Wait
now that I think a little more from the axle to the bottom of the top clamp.

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post #17 of 46 (permalink) Old 03-27-2011, 08:31 PM Thread Starter
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Quote:
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If the new stuff is with in an inch or so from bottom clamp to axle from the old stuff Mount it up .
You may need to find and fit custom bearings for the neck.Although very technical not that much time machining a little more on design.
I did all the research before hand on the fork swap, and the bottom bearing is a direct fit into the stock CB frame (OEM was 30mm, this GSXR fork is 30mm) - but the top needs some love.

All Ballz sells a conversion kit for the top that bridges the 48.5 outer to the 30mm GSXR inner, but its kind of expensive so I may buy a more common 48x30 and shim to 48.5mm.

The biggest problem I had was getting the stock front wheel onto the 25mm GSXR axle. I can buy wheel bearings that go from the CB outer to the 25mm axle, and be cheap and use 1" pipe (25.4mm) as an internal bearing spacer, but I need to machine the 25mm spacers to center the wheel in the wider axle, and then redrill the rotors I have to the CB bolt pattern. - And that assumes whatever I've done hasn't messed with the stock caliper spacing (necessitating a custom caliper bracket).

So I'm trying to decide whether its worth the trouble of swapping this on, or just rebuilding the stock fork with an external preload adjuster (here - http://www.400fourstore.com/Merchant...ategory_Code=C ) and slightly heavier oil.

I think for this first build (and 1st bike) - since I don't have another to ride while this one is down - I may be better off going the easier route - even if means holding off on my final 'vision'.

Too bad though - the modernized 'cafe' style retro bikes are rad!

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post #18 of 46 (permalink) Old 03-27-2011, 09:14 PM

 
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First you must make the old hub match the width of the wheel from the new forks.

Then make caliper carriers on the new forks fit the old wheel width at the disc.

And ofcourse axle dia.for this you'll need bushings for the new forks as the old axle will be smaller in dia.

Good luck

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post #19 of 46 (permalink) Old 03-28-2011, 11:00 PM Thread Starter
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It Runs!!!
Not well... And not for long, but it was 30 or so degrees out and I was jumping the starter relay with a screwdriver.

Concept proven though - it runs. Now it's time to start ripping it apart and making it suck less!

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post #20 of 46 (permalink) Old 03-28-2011, 11:09 PM
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Nice starting point (eek!).

I'd go with superbike style bars; they're the easiest to ride with (clubmans are HARD on the wrists after an hour or so). You may need to swap out with shorter cables or be careful in routing them so they don't get in the way of other stuff.

Keep working on the running part. You'll need to ride it around to see if it needs a trans or clutch or some other items. Once you have that sorted out, go crazy on the mods or whatever.

Good luck and looking forward to updated photos!

(I had a 1978 CB550K that I tricked out with mac 4-1 and superbike bars. The thing was slow as a dead horse and stopped for crap, but it was a fun bike to tool around on!)
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post #21 of 46 (permalink) Old 03-30-2011, 04:28 PM Thread Starter
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No progress over the last couple days, but I'll be making up for it over the next few.
In the meantime, I had some downtime and made this progress (and photoshop) of where I'd like to see it go (+/- a few changes.)


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post #22 of 46 (permalink) Old 03-31-2011, 08:23 PM
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This looks oddly familiar.
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post #23 of 46 (permalink) Old 03-31-2011, 09:08 PM Thread Starter
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User name should have given it away... Welcome to my thread!

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post #24 of 46 (permalink) Old 04-01-2011, 07:38 AM
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I like the photoshop! As crashomon stated, the cafe bars look hella cool but are horrible on wrists after a while. I was in a lot of pain (felt like carpal tunnel) after a ride to rockerbox. The superbike bars should be easier on you. Upgrading the suspension to something newer really makes a huge difference. I took the plunge and got some Hagon shocks for mine and my bike stopped bottoming out all the time, now I am going to look for newer fork springs! Any plans for the front fender? Before you ditch it or chop it, have you considered putting on a pedestrian slicer? I kinda regret not doing that with mine. Also mentioned by crashomon is the weak brakes, they SUCK on these old bikes. Looks like you are upgrading to something modern so that is going to help a lot.
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post #25 of 46 (permalink) Old 04-01-2011, 08:29 AM
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Per the brakes, Mine stops wonderfully now, I took the caliper apart, cleaned it all out, put on a stainless line, then a modern mastercylinder, huge improvement. You don't even need a high end master to make a big difference, I got a generic one off a moped website that works great and was cheap, $25. If you're feeling more spendy any modern sportbike master will probably work, but since you only have one caliper instead of two it might be a bit touchy.

http://www.treatland.tv/front-brake-...r-cylinder.htm

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post #26 of 46 (permalink) Old 04-01-2011, 02:17 PM
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Yep I got the same version but in grey + chrome. They also pop up on ebay a lot as "CB400 master cylinder". Helped out a lot!
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post #27 of 46 (permalink) Old 04-01-2011, 02:58 PM Thread Starter
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Thanks for the suggestions on the new MC - salvaging mine may be more trouble than its worth!
I keep trying to decide whether a new MC & SS lines (+ drilled rotors - though I don't expect them to do anything) will be enough braking.

1/3 of me wants to stick to the fairly basic photochop I had above - and understand its limitations but get riding fast.

1/3 of me wants to graft in a modern front end & go balls to the wall on the project knowing it'll take a while.

& 1/3 of me wants to build a CR750 style 'repli-racer'...

decisions....

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post #28 of 46 (permalink) Old 04-01-2011, 03:12 PM
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I would suggest you build it as a simpler basic build, get it rideable, learn to ride and upgrade it as time goes on. Or maybe instead of dumping $5-6k in upgrades into that old bike maybe keep it in rideable condition and buy a modern bike for your daily rider. These old bikes are fun projects and great for toodling around on, but a modern bike gives you far better reliability, comfort, handling, braking, and accelleration.

Also, buying a new master is far cheaper than rebuilding that stocker, atleast in my case. I got my master for $25, a rebuild kit for my stocker was $75 + the time to actually do it. Time and money better spent on other aspects of the build.

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post #29 of 46 (permalink) Old 04-01-2011, 03:44 PM
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+1 on EEJ's advice: Keep it simple. Ride the snot outta of it and upgrade as you go. Otherwise, you may spend too much time/effort/ca$h and find out it wasn't worth it. You will get 25% of what you spend on it back; are you SURE you want to do that? (To clarify, if you spend $5k on this bike, you'll be lucky to sell it for $1500. Times are tough, and there's a bajillion bikes out there).

Handlebars, Brake and Suspension improvements along with pipe and jetting will make a huge difference. (drilling rotors is more show really, might want to hold off on that).

Then again, motorcycling is all about what make YOU excited; we're just offering some tips of wisdom; you don't have to follow them.
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post #30 of 46 (permalink) Old 04-01-2011, 03:51 PM Thread Starter
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^^ No, I appreciate the advice & wisdom!
I'm a bit obsessive, and the idea of doing anything half-assed (or more accurately, less than 110% ) bothers me.
But the reality is, I bought this bike because it was sub $500, and that was about what I could spend on a bike - so as much as I'd like it to be world class when finished, I need to understand what it isn't (a modern sport bike) - and understand what it can't be (a non-ending, high $$$ project).

Plenty more bike builds for that in the future!

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