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Old 02-12-2014, 04:38 PM   #106
Sourjon
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Location: Louisville, KY
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Picked up a 71 Monday and just started to look for build threads. Like what you're doing. Keep it coming.

John
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Old 09-07-2014, 04:41 PM   #107
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Hillbilly Primary Shaft Slide Hammer

Back at it lately. To extract the primary shaft from a CB500 crankcase use the rear engine mount plus a 36mm socket. Place a washer on the nut to protect it. Replaces the official Honda primary shaft slide hammer removal tool. Problem solved.

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Old 09-07-2014, 09:43 PM   #108
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Here's my K0, first road registered in New Zealand late February 1971; I restored it in about 1996, IIRC.

It was a really good road bike, so I removed the lights and stands, put a 4-1 and a braided front brake line on it, did a bit of lockwiring, and took it to Phillip Island January 2003 when I was racing some real historic racers as well.



It was hilarious; WFO the whole time, did 2:10s, backing it into MG and buzzing down Doohan Straight with my left hand holding the fork leg....
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Old 09-19-2014, 06:03 PM   #109
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Great seeing the old bikes on the track pjay!

All clearances and specs are good, crankshaft bearings, ball and roller bearings, starter clutch, rods, transmission, shift forks, all well within specifications. No apparent significant wear on anything.





All transmission dogs and engagement slots show no wear or rounding. Amazing for an engine with about 31,000 miles, according to odometer, and unknown history, likely involving some hillbillies along the way.



Bottom end is now going back together with new OEM Honda seals, primary chain and cam chain, and then to be slung into the frame, the rest will be built on from there.

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Old 10-14-2014, 06:57 PM   #110
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Closeup of transmission.



Crankcase halves assembled.





Torqueing the bolts.



One bolt went in normally, finger tight, put the wrench on it, and it snapped before even starting to get tight. Must have fractured on removal and was ready to break.



Oh well, new bolt ordered, and back apart the crankcase halves come.
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Old 10-14-2014, 08:30 PM   #111
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Good to see you back in the game, we're watching.
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Old 01-03-2015, 03:30 PM   #112
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Back at it. That broken crankcase bolt was extracted and replaced, crankcase halves are now back together, again. Starter motor dissassembled, cleaned, inspected, continuity checked.



It was filthy.



New brushes and brush springs installed.

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Skowinski screwed with this post 01-03-2015 at 04:03 PM
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Old 01-03-2015, 03:31 PM   #113
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Oil pump dissassembled, clearances checked, all ok. Reassembled with new oil pressure switch, 0-rings, and screws.

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Old 01-03-2015, 03:35 PM   #114
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Triple clamp assembly with new tapered roller bearings, greased.







Rebuilt forks with new Forking by Frank (Franks Maintenance and Engineering) chrome inner tubes installed.



Rebuilding the wheels is next up.
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Old 01-03-2015, 03:43 PM   #115
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Almost forgot, of course when the new drain bolt and washer (original bolt was butchered) was installed and torqued it stripped out the threads in the oil pan. I couldn't count the times I've ran across this problem with used bikes. It seems most that venture so far as to change their own oil feel it's necessary to reinstall the drain bolt like a gorilla would. Repaired the threads with a heli-coil insert and mounted the pan with a new 0-ring.

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Skowinski screwed with this post 01-03-2015 at 04:09 PM
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Old 01-03-2015, 04:07 PM   #116
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Quote:
Originally Posted by Skowinski View Post
Closeup of transmission.



Crankcase halves assembled.





Torqueing the bolts.



One bolt went in normally, finger tight, put the wrench on it, and it snapped before even starting to get tight. Must have fractured on removal and was ready to break.



Oh well, new bolt ordered, and back apart the crankcase halves come.
Or you are actually from Krypton, and just didn't know it.
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Old 01-04-2015, 04:14 PM   #117
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Original front wheel on the bike.


Cleaned up hub and new spoke/nipple set.
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Old 01-04-2015, 04:19 PM   #118
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Starting to lace up the hub to a cleaned up rim. Since this was a first time lacing up wheels, the order was a bit off and had to take some back out and start again.


Done.


Truing it up. Still working on that, it's a bit tedious for a beginner.
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Old 01-09-2015, 11:28 AM   #119
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The rear wheel, sprocket removed and cleanup started. The old tire is from Sears, I'm sure that dates back a few years, and it appears to be made of hard plastic now. The spokes are toast, heavily corroded.

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Old 01-10-2015, 02:35 PM   #120
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The rear sprocket carrier is held on by the reverse-threaded stainless steel retainer ring with 4 holes in it. Honda used to make a special tool, of course. I went to Lowes, bought some stuff, and fabricated a tool, it got bent up getting the ring off, but worked.



For anyone else planning this, be aware that the damn thing is staked to prevent it from unscrewing... the only problem is the staking was done through the holes, and I couldn't see it. Didn't read about it anywhere either. I had no idea until it finally came off, so I basically was a gorilla on this one. The threads seem ok though.

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