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316  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 18, 2012, 11:41:13 PM
If the shift drum is anything like a 750s, you will need to take the neutral switch out, which is on the bottom of the 750.  Not sure about that funny connector.  Maybe search the main boards and then talk to anders just to be sure.

Anders has already been in touch! Grin

He sent me a text shortly after posting telling me to remove the stuck screw (funny connector) with a better impact driver; one with an interchangeable 3/8" or 1/2" drive. I have to bring the cases to him soon anyway for help removing the primary chain, drive and crank, so we can use some sweet tools then.

Anywho, once that is done I can clamp a slide hammer onto a 6mm screw or threaded rod, insert it into the ball-bearing end (into the shift spindle) and pull it out. Until then I will be tearing down the other motor and getting it to the point where I can bring it all up to NH for one-stop shopping.
317  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 18, 2012, 10:37:54 PM
Quick picture of the spare engine courtesy of Santa's delivery on Saturday. Treeve, feel free to throw up a pic of YOUR present Tongue

318  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 18, 2012, 10:34:32 PM
After work today, I decided to come home and continue clearing out the innards of my split cases in my new "workshop" Grin ...

BEFORE:






AFTER:






Trisha's office has become my garage but she's a trooper about it (notice her drafting table is still there!).

So as said above, I am working on removing all parts of the cases that can be removed in order to prep for a thorough cleaning and new paint job.

Starter motor gears


Kick-starter shaft and gearing






Shift drum




Shift forks



Now onto the question of how to remove the shift spindle? It has some ball-bearings on one end and a funny looking connector on the other side. I aired on the side of caution here as to not start forcing things apart. That funny connector also has a very difficult screw; even with the impact driver. Ears are open for "how-to's"...





319  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 17, 2012, 09:21:15 AM
Appreciate that Ben. I figured he would be filled to the hills with emails, so any better way of getting in touch would be a huge help.
320  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 17, 2012, 02:33:16 AM
I have an email into Mike about a few things. I'm just waiting to hear back from him. Keep throwing suggestions my way as I am making a list of things to do and some are not there already. Thanks guys.
321  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 16, 2012, 05:07:26 PM
Sounds like you got a plan. 

Um, uh, yeah, I guess Grin

I might've already said this above, but the plan is to tear down the parts motor and extract the crank, rods, pistons and cylinder. I might possibly match up some rockers as a few of mine were pitted and could use replacing. The engine is off of a '75 550 if I recall, and for $150, a couple gallons of ice cream, a few pots of coffee and some nice Italian dinners I might be able to get it back up and running.

Nevertheless, I am planning to spend time going through the frame, electrical and carbs while everything is off; not necessarily dumping cash into those areas but definitely cleaning up and getting the bike in tip-top shape.
322  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 16, 2012, 03:57:20 PM
Looks pretty gnarly.  If you spray them down with a little WD40 after the soak, it should prevent the flash rust.  Are the rods still usable with new bearings?

Good call on the WD-40. I was wondering what to do with them after the vinegar bath and thorough water rinsing...

For the rods, I questioned the same thing but Anders seemed to think that the fact they went through a failure, it would be best to source new ones as they might have been thrown out of tolerance due to abuse.

I'm fairly certain I could check them to Honda specs and determine whether they are good or not, but with the spare motor en route Saturday it is not high on my to-do list as I am planning to use the ones from there.
323  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 16, 2012, 12:48:19 PM
As promised; a few detail shots of the crankshaft bearings and pistons. It definitely doesn't look pretty but I guess it really shouldn't...


Forgive some of the flash rust below; I was trying out some white vinegar.



Bearing from cylinder #1 rod



Piston from cylinder #1



Piston from cylinder #4

324  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 14, 2012, 12:58:15 PM
Woo! Just heard back and have a new motor to tear down and pull from. According to Anders I can use the pistons, cylinders, oil pump, crank and rods. See you Saturday, Treeve!
325  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 14, 2012, 12:14:36 PM
Quote

if a 750 fits in the back of an Altima, 550 will work in a Camry.  Just make sure to put down plastic....don't ask me how I know.  If you don't have any, don't worry, I have extra. 

So what happened to that other spare 550 you have?  How's the engine in that thing?

Alright, if you've done it before in an Altima I should definitely be fine. Her Camry is very new, so plastic is a must or else my engines and I will be looking for a place to live.

The other 550 is in good condition. All the parts are there to make a second good stock runner. I haven't been into the engine at all, so it's still a mystery and not worth swapping or parting out if my intentions are to get it going as bike #2.
326  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 14, 2012, 11:31:50 AM
Quote
I am betting the little birdie has a beard, chugs coffee by the pot and knuckles ice cream by the gallon.  Grin  You coming by at 9 am too?  I think he said he is going to have an engine for you. 

I'm waiting to here from him, but I'd love to see the delivery of the 350 and then I could always try to cram the engine in the back of the girlfriend's Camry.
327  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 14, 2012, 11:28:44 AM
The engine is going to be rebuilt (you're right, Peter, that's all the fun Grin ).

Anders and I talked quite a bit about what to do with it once we split the cases, and I liked the idea of keeping my serial numbers matching as well as learning a ton along the way. He is going to look at an engine for me today and should be reporting back shortly about condition and worthiness. My hope is to tear into that and pull the pieces I need, all while retaining the original cases.

On a side note, the girlfriend is not too happy to have one engine disassembled in the front porch and another whole one potentially on the way. Women... Tongue Lips Sealed
328  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 13, 2012, 10:39:56 PM
Cool! So now you are going to build one really nice CB550!

You trying to say it wasn't very nice before!? Haha.

I'm hoping to get it all cleaned up; degreased, polished and possibly painted. Maybe I'll lose some weight and pump it out to 600cc so I can keep up with the crazy man on the Ural.

BTW Treeve, a birdie tells me a 350 is coming down on Saturday? Congrats!
329  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 13, 2012, 06:40:48 PM
Many will now want to know my take on the failure, or perhaps Anders' take as well. We had much time to discuss so I'll leave a hybrid version here.

The leaks I have been finding from the oil pump led me to source a new o-ring for the cover of the pump. If the cover is proud of the pump (even just >.001") there will not be sufficient pressure. It looks as though my cover fit these criteria. Therefore it is believed, in theory, that the oil was sufficiently pressured into the top end but the pump was not exerting enough force to complete the full delivery cycle, in essence starving the bottom end and thus creating this dilemma.
330  Motorcycle Stuff / Honda SOHC4's / Re: The Top End Rebuild Thread - 1977 CB550 on: November 13, 2012, 06:18:44 PM
Ladies and gentlemen, boys and girls, children of all ages; the moment you have been waiting for...

(Curtain opens. Crowd goes wild with excitement)




I bring you a story about thinking you know what's broken and knowing what is broken.

Anders came to visit me in the quiet country town of Acushnet, where we promptly fired up the air compressor, aircraft-grade impact driver and coffee machine. From the get-go we were under the impression that the damage would be located within the top-end, so we made a quick go of pulling the breather and valve cover. The amount of PO orange gasket sealant made me wonder how the bike was running so well and never sucked a loose flap into the cylinders.







We were both surprised that the top end looked so healthy, but it left a big question mark on what the cause of the awful squeaking might be during start up. Onward we forged; off with the head!



Oops, we forgot one screw and took the jugs with us on a good thrust up.



Alas, we find some sticky pistons (1 + 4) and a chip on the sleeve of cylinder 1. In addition, 3 of the 4 pistons are not moving a freely as they should. Again, 1 and 4 are the worst culprits, requiring forceful movement on my behalf, while 3 just seems a lazy. It's not looking so good and I'm not feeling so hot at this point.





Notice the rubbing marks on the following two photographs:







On a side note, what the heck is this blemish behind the oil filter? Looks as though it's been JB-Welded, but Anders and I were both very confused as to why?



Now knowing that the rods, bearings and crankshaft were shot we took to splitting the cases. Anders broke out the impact thing-a-majig and made quick work of 35 year old screws, but we quickly hit a snag when going to disassemble the primary chain and realizing the right tools were not among us. I don't have any good close-ups of the damaged bearing and crankshaft, but I did bring the engine back to Boston so that I can work out of my apartment and will get some detail shots eventually.









The mighty 550 has temporarily fallen and been left naked in the garage...

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