CBX550 Restoration Project

[mister c]

People have been showing an interest in my CBX550 project, so I will start this thread to show what I'm up to.

The year was about 1990 & my 1st big bike was Honda's CBX550. I had been a massive 2 stroke fan & had been riding X7's GT380s etc, so this was my introduction to inline 4s. I loved the shape of it & also the speed, but, unfortunately, couldn't afford to keep it. I sold it 6 months later & ended up with a cheap & cheerful CB250RS to go to work on.
Every time I saw a CBX, I always thought "one day, I'll get another one of those". Well, 25 years later I saw an advert for, not 1, but 2 550's for £650, been stood in a yard for over 5 years. I couldn't resist & offered £400 for them both. To my surprise they accepted, so i made the 300 mile round trip & picked them up. Boy, were they in a state, but I had decided that I would restore the unfaired & use the faired one as a donor bike.
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10647006_10204676565933507_773517591500170591_n.jp g?oh=b940e9820c194c9de1de931058940b94&oe=55085714

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https://scontent-b-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10615480_10204676564253465_3741164393269268838_n.j pg?oh=742c5d5f33bec294a6edfcba96c06ca6&oe=5501E05B

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10565039_10204676569173588_8096441168331193554_n.j pg?oh=b7117467d06c6ac18470a32a942261cf&oe=55005653&__gda__=1425635638_0eda2fedfafef175047929a4c823983 c

Also in the deal was this little lot.
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10603503_10204676575813754_5485107888630984099_n.j pg?oh=2843ef9832ae7dbe277b1d0e3884afee&oe=55007973

So, 1st things 1st, it was time to start the strip down. I was dreading it because 33 years of abuse didn't bode well on the nuts & bolts. Unbelievably every nut, bolt & washer came off without any problems at all.
So, I had a frame, loads of bolts, an engine, 2 wheels & an exhaust in bits. I sent the frame away for powder coating at Rtro Coatings near Crewe & what a fantastic job they did with it too. Every screw hole (except 1 that he missed) was covered before blasting & coating. It came back like new.
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10411139_10204812529332507_3862350817966636319_n.j pg?oh=565b1eda9bc031acc1be713165841873&oe=5545A7F2&__gda__=1425649815_e0e010e74b166422cb15537ec70ec37 b

https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10646689_10204812527652465_2739938963907288653_n.j pg?oh=7b5641f2e7ace30029e87504d7137de8&oe=55176787

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/1909729_10204812529892521_1261374616654626105_n.jp g?oh=3d2ca493d36066c9b53edec287d4ac99&oe=5505C03D&__gda__=1426588554_b33d62ffb583730f7dd777b7887939b a

At the same time I sent off all of the nuts & bolts to be zinc plated. I now know that they should have been nickel, but it's too late now.

Next installment will be about the rebuild.

[maviczap]

One of the sweetest handling bikes i ever had and i even liked those inboard discs even though they were a pain to work on.

Apart from the dreaded camchain problem which caused me to sell mine, it was one of my favourite bikes I've ever owned.

Good job i didnt see that ad Col, i would have been very tempted

[mister c]

I've just sold the other one mav. Went for 200 quid

[maviczap]

Dang, still its a good job you're too far away Col, otherwise I might have bought that one!

Did you keep the better one, was there more wrong with the faired one?

Or was it a case of too many projects?

[Jayneflakes]

Ooh, I am all excited already. Good show Mr C, jolly good show indeed.

I await the updates with anticipation. :D

[mister c]

Here's part 2 while the missus is watching Emmeroid Farm.
So, I had the frame back from the powder coaters & my assortment of bolts from the platers, I thought it was time to start cleaning & painting stuff.
The brakes were in a right state, but after a good old session with a mini grinder & wire brush attachment, they came up quite well.
I also found some high temp paint that virtually matched the colour of the brake covers :)
http://i5.photobucket.com/albums/y177/croozenooze/2014-09-22065928_zps2de9e90b.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-09-22065928_zps2de9e90b.jpg.html)

i cleaned up the swingarm & gave it a coat of silver paint & started to rebuild the ProLink suspension arms. The suspension bushes were completely shot, but, luckily the "donor's" were ok, so were knicked as you can't buy them anymore.
http://i5.photobucket.com/albums/y177/croozenooze/IMG_4025_zpsbd2be962.jpg (http://s5.photobucket.com/user/croozenooze/media/IMG_4025_zpsbd2be962.jpg.html)

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10620737_10204816252465583_5668906036637333767_n.j pg?oh=88b02a24f479c77ee7d6dfd65c2cb67d&oe=55143060&__gda__=1426802719_cc411b58cd621883f6072ec86d7ade3 d

All fitted & greased up. New springs & rear shock painted up.
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xfa1/t31.0-8/s960x960/10669026_10204833667180940_5916491495792447118_o.j pg

I also cleaned up the exhaust system. i was amazed after a lot of elbow grease, time, Autosol & wire wool at how well it came up.
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/t31.0-8/q85/s960x960/10694463_10204783624009892_9207429127222620531_o.j pg

So, with the rear wheel cleaned, brake covers sorted, swing arm & suspension sorted I put it all back together. I also cleaned the rear mudgaurd with some Auto Glym plastic polish, what wonderful stuff that is :). As you can see in this picture, I'd also cleaned & painted the front wheel as well in anticipation of doing the front end
http://i5.photobucket.com/albums/y177/croozenooze/2014-09-22072838_zps4ffa8894.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-09-22072838_zps4ffa8894.jpg.html)

[maviczap]

Pretty good going already Col.

I don't think many will have the OEM exhausts, mine rotted through the back on the RH side near the footrest hanger after less than 6 months if I remember correctly. It was replaced under warranty and I kept it as new in the loft until I sold the bike

I fitted the Motad one you've got

[andrewsmith]

It's good to see this written up Col

[squirrel_hunter]

Liking this, keep the updates coming.

Also that exhaust looks like new, how long, and what process did you follow if someone were looking to repeat that finish?

[BanannaMan]

Looking good!
I like the odd enclosed disc set up, although I wonder if it wasn't as much for the cafe racer look rather than for water protection
Either way it looks great after painting!! And gives the bike a distinctive look.

[mister c]

Liking this, keep the updates coming.

Also that exhaust looks like new, how long, and what process did you follow if someone were looking to repeat that finish?
I actually said to my son that it looked like surface rust on the downpipes, so, with mini grinder in hand, attacked it with a wire cup brush. Once most of the "proper" rust was off, I attacked it with Autosol & wire wool. It still needs finishing off with Autosol & a cloth. One downpipe is quite pitted, but I don't want it showroom quality as I intend to ride it when it's finished. The silencer just cleaned up with Autosol.
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10702168_10204783622569856_461990910985933479_n.jp g?oh=d2023b4b66ac94d16995c9235d2dbb38&oe=5504CFAB&__gda__=1426883218_2955fb53a8a96d27cc32bd372fee88e b

Looking good!
I like the odd enclosed disc set up, although I wonder if it wasn't as much for the cafe racer look rather than for water protection
Either way it looks great after painting!! And gives the bike a distinctive look.
It's a shame that they were such a pain if not looked after Bill. That was their biggest pitfall really

[mister c]

So, with the rear end sorted, it was time to move onto the front. 2 sets of forks were completely knackered, so it was time to think about getting a set rechromed. I then remembered that I had another set in my box of spares, so unwrapped them out of their bin liners. They were in pretty good condition, couple of pit marks, but very useable. I had previously ordered some new fork seals & headrace bearings ready for the build, so set to stripping the forks down.
The big thing in the 80's was Anti Dive, which, from what I heard, didn't really work anyway, but a good selling point I would have thought. The seals were shot at on 1, so robbed them off one of the other sets of forks.
Knackered seals at the top "new" ones at the bottom.
http://i5.photobucket.com/albums/y177/croozenooze/CBX%20550/IMAG0086_zps21b26795.jpg (http://s5.photobucket.com/user/croozenooze/media/CBX%20550/IMAG0086_zps21b26795.jpg.html)
http://i5.photobucket.com/albums/y177/croozenooze/CBX%20550/2014-09-24195121_zps4f2f929e.jpg (http://s5.photobucket.com/user/croozenooze/media/CBX%20550/2014-09-24195121_zps4f2f929e.jpg.html)
http://i5.photobucket.com/albums/y177/croozenooze/CBX%20550/2014-09-24193740_zpseaaf9b18.jpg (http://s5.photobucket.com/user/croozenooze/media/CBX%20550/2014-09-24193740_zpseaaf9b18.jpg.html)
Now it was time to attack the fork seals. 30 years of abuse had taken their toll, boy were they a pain to come out! One set of scrap fork legs.
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Good job I have 2 other sets lol.
Time to fit on the yokes "triples". I greased up the new bearings, but found them very difficult to fit, which I haven't sorted properly yet. The front end will have to come off again & I'll do a bit of sanding on the powder coat.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xfp1/t31.0-8/s960x960/10687956_10204813591279055_6137647545387088810_o.j pg

I also cleaned up the clocks with good old Auto Glym. I was astonished at how well it brought life back to the plastic. It comes in handy having a mate that owns a valeting company for that piece of advice :)

Before.
http://i5.photobucket.com/albums/y177/croozenooze/CBX%20550/IMAG0033_zps719a2725.jpg (http://s5.photobucket.com/user/croozenooze/media/CBX%20550/IMAG0033_zps719a2725.jpg.html)

After.
http://i5.photobucket.com/albums/y177/croozenooze/CBX%20550/IMAG0034_zpsimfsojfc.jpg (http://s5.photobucket.com/user/croozenooze/media/CBX%20550/IMAG0034_zpsimfsojfc.jpg.html)

So, forks painted, clocks & yokes fitted, we're getting to see a rolling chassis at last.
http://i5.photobucket.com/albums/y177/croozenooze/CBX%20550/IMAG0087_zps434d8700.jpg (http://s5.photobucket.com/user/croozenooze/media/CBX%20550/IMAG0087_zps434d8700.jpg.html)

https://lh4.googleusercontent.com/-0-xfj9VoYs8/VIvvJuXE3VI/AAAAAAAARK8/LtUKLKI4Eng/w1107-h626-no/2014-09-23%2B19.49.46.jpg

[Geodude]

Superb, a build thread at last :) keep up the good work.

[Redmist]

Yea another great build thread, cracking job so far.

[mister c]

Most of the large parts were starting to look quite good. i was wondering when something was going to go wrong. Well, the engine was going to be the subject of a lot of head scratching (& to be honest, still is). Before I started the strip down it was imperative that the engine ran. I didn't want to waste a shed load of money & time doing this thing up if the engine was knackered. So, with the bike being stood for over 5 years, stale fuel, old plugs & oil, it was time to fire it up, if it would. My son & I checked a few things out before cranking it over & all seemed fine. I fitted the battery off my other half's 125, she wasn't doing anything with it anyway, turned the key & cranked the engine over with the kill switch set to off to get a bit of oil circulated. Then, with a bit of trepidation I hit the button & left it depressed for a little while. We had a cough, cough, splutter splutter, then she fired into life with a massive cloud of smoke.
UCVJgH8kQFw
So, I knew the engine ran, I thought I was being clever by just cleaning & painting the motor, polishing the rocker & generator covers & fitting new spark plugs. BIG mistake!
My son came down to give me a hand fitting the engine, it took a while, but she went in & looked really nice.
https://scontent-b-ams.xx.fbcdn.net/hphotos-xaf1/t31.0-8/q81/s960x960/10680120_10204888882161280_8735329754310482533_o.j pg

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I fitted most of the electrics after a lot of cleaning up & checking to see if everything worked. We now have what looks like a motorbike. Footpegs cleaned & fitted too.
https://lh5.googleusercontent.com/-X0AQ092Mv5g/VIvw0msBFuI/AAAAAAAARNA/NDU6ehj8_D0/w1107-h626-no/2014-09-28%2B20.14.53.jpg

https://lh4.googleusercontent.com/-NNdMpZPrAkw/VIvw3UB7JqI/AAAAAAAARNI/njBhPpwKnCQ/w1107-h626-no/2014-09-28%2B20.34.18.jpg

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I was having a real problem with the rear brake master cylinder, they are as rare as rocking horse droppings & both of mine were siezed solid. Even started looking at alternatives, which were few & far between. I did find a CBX1000 new one for only £700 +VAT :p
I had soaked one in WD40 for weeks, but still couldn't move the piston inside, so gave up. I found one on EBAY for £40, so snapped it up. The rubber seal was broken, so thought I'd order a new piston kit from David Silver Spares, only £55.00 lol. While I was waiting for it to arrive, I had a play with original cylinder. I drilled a hole into the old piston, took a long self tapping screw, screwed it into the piston, put the screw in the vice & tapped the cylinder with a mallet......... Hey presto :)
https://lh3.googleusercontent.com/-ZxTsDTbPsUg/VIv0xLKbyNI/AAAAAAAARVw/3pRDJOBzL_E/w1107-h626-no/2014-11-15%2B09.20.46.jpg

[BanannaMan]

So, I knew the engine ran, I thought I was being clever by just cleaning & painting the motor, polishing the rocker & generator covers & fitting new spark plugs. BIG mistake!

https://scontent-b-ams.xx.fbcdn.net/hphotos-xaf1/t31.0-8/q81/s960x960/10680120_10204888882161280_8735329754310482533_o.j pg







It was all going too well up to this point. ;)
What's up with the engine???

[mister c]

It was all going too well up to this point. ;)
What's up with the engine???
I'll come to that bit a little later as it's still giving me major headaches.

Forgot I had this picture. This was the rear master cylinder when it came off the bike.
http://i5.photobucket.com/albums/y177/croozenooze/CBX%20550/temporary_zps6f5b14c4.jpg (http://s5.photobucket.com/user/croozenooze/media/CBX%20550/temporary_zps6f5b14c4.jpg.html)

I turned to the brakes next. i had already cleaned up the discs, but now turned to the calipers. I purchased a new set of stainless brake lines with black covers to keep with the "standard" look. I filled the master cylinders with fluid & bled the brakes to see how badly siezed up & rusty they were, again I was really surprised, they were in pristine condition. After cleaning 30 years of crud out of the calipers I noticed this on one of the front calipers.
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xap1/t31.0-8/s960x960/10700267_10205119525687224_897163798810092206_o.jp g

Time to root through my box of bits & turned up another front right hand caliper. Re bled the system, pumped out the pistons, cleaned & re-fitted &, hey presto, we now have front brakes :) I did the same with the rear with no dramas. Got myself onto Ebay & bought a full set of brake pads.

All cleaned & ready for copper grease.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xap1/t31.0-8/s960x960/10714357_10205119526007232_5400050470078093466_o.j pg

All fitted & looking nice. Time to fit the covers.
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xaf1/t31.0-8/s960x960/10749901_10205119526367241_818591835776802700_o.jp g

Rear brake fitted.
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10615421_10205143874815937_113966193355941960_n.jp g?oh=209557a4bbb057e60566f454846419ce&oe=5506B768

One problem I did come across here was that the brake kept catching & I couldn't understand why. After a lot of head scratching I found that the front & rear pad retaining pins were a different length. It took me ages to find it too :confused:.
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10420289_10205139270100822_2117611526107656101_n.j pg?oh=be7cb6517c1f03c0b8ec35a7ad629f2b&oe=55020DE3&__gda__=1430072821_ea60daff5e0c487970b5577396f6c7f 2
I walked into the shed the following morning & found a pool of brake fluid on the floor. The front master cylinder was leaking quite badly, so it was back onto Ebay on the hunt for another one. I found a Chinese copy for £20 & thought "now, do I trust it, or buy a 2nd hand one?". After looking on David Silver's website, I bought it. He had the same one on his site for £30, so they must be ok.
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10846114_10205370420199430_754478579406427022_n.jp g?oh=27366b68a16a67f7c78f433edf643f35&oe=54FD1E33&__gda__=1426800985_3bc0bc1f9067c8c00f5a42c2d5716d4 e

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So, it was time to fit the exhaust. I contacted Motad to see if I could still buy the cones that hold the downpipes to the engine. "yes sir, it's part number blah blah blah & they cost £6 each". "I'll take 4 please". Happydays :)
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10422159_10204991547287844_1584617210974816923_n.j pg?oh=5dba15891da2408d626448464e0c080c&oe=54FCD32E&__gda__=1430464312_6aaf561f27fccf7ed56938185bdf4d2 d

So, I cleaned up the oil cooler & pipes, refitted it.
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/1690700_10204991545767806_430646482074288497_n.jpg ?oh=8ce80e2540aba0031ce10b1a506a4393&oe=550A970E&__gda__=1430114258_3301c66e1e31e3d080d2444edd60d65 e

New oil filter fitted (was in my box of bits:))
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/1011741_10204991544487774_2397736505676867077_n.jp g?oh=3d57dd8e0d51e2aea777677240908ba2&oe=550088E5&__gda__=1426762716_67fdb3875a4b4990c5bc297e9654cfb 0

Cleaned up the exhaust holders
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10557419_10204976745037797_2231075513203435009_n.j pg?oh=46fb23b1fc4351dfd1f27f15f6b4f968&oe=5546DEA0&__gda__=1430469829_eb26395e4c5eb2d798cfb28274ceec6 5

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10665770_10204976744357780_789999998006723901_n.jp g?oh=831c9e1d8d024e9ba56c703a6fca7924&oe=55430BD5&__gda__=1425925982_02de8a8c60df6ad28eaf48ce5d0e464 7

And refitted the exhaust. I was getting really excited at the prospect of starting the bike up now.
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/10171074_10204991545127790_6905586740778315426_n.j pg?oh=1cb093716e21743c0546215a3c97e15f&oe=550AED2B

[Geodude]

Looking really good so far :)

[NTECUK]

I vaguely remember the cbx.
Well I did like the look of the 750 in black.
Nice job there.

[mister c]

Cheers guys.
Right, it was time to fire the old girl up again. I was very disappointed to say the least.
EjVzkjTy_l4

Time for a top end strip down. I had a suspicion it was valve guide oil seals after being stood for so long. Back onto Ebay & purchase a gasket set & start to strip the engine.
I have repaired single cylinder machines & multi cylinder 2 strokes, but never a DOHC 16 valve in line 4, so this was going to be a massive education.
Seeing as I was taking the head off, I thought that I would check the cylinders & piston rings for wear, so it made sense to buy a Glazebuster & hone the cylinders while it was apart.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10731067_10205266336677407_7998647748950458605_n.j pg?oh=efddf9afa3b8bcfb847b268d3884628c&oe=550A9820&__gda__=1425605471_b8b928d1249ca16244f3af09bae1b1d 4

So, out came the haynes manual & I set to work. Truth be known I was cacking myself, but, if the worst happened, I'd got 2 spare engines to play with. It came apart quite easily, but there was something that didn't make too much sense, the timing was miles out, so how it ran, I'll never know.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10645000_10205245445395138_6545261295604126516_n.j pg?oh=e6d42cf121d98e552c9b808a97cc8614&oe=54FD36DC&__gda__=1426713290_f1141022de7f6e71a3ab20f7e068a64 6

Never mind, I'll sort that when I rebuild it. I removed the camshafts & laid everything on the bench in the order it came off the bike.
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10384044_10205248271385786_67596234642982325_n.jpg ?oh=eafcbd6a8ebc83e2378f90b01ab4cc9f&oe=554213F8&__gda__=1430562368_7c4115f346ed2f275338d9527ac8554 8

So I removed the head & slid the barrels off the pistons to have a nosey, again, for a 60000 mile engine, it looked fine
https://lh3.googleusercontent.com/-2UnVSY17yt4/VIv0p0SJn3I/AAAAAAAARVY/xhbElUOkQxo/w354-h626-no/2014-11-15%2B06.40.35.jpg

I checked the piston ring gaps too, they were in tolerance .
https://lh4.googleusercontent.com/-DGszTfdNN7A/VIv0uCr-XcI/AAAAAAAARVo/bG0olWAh-Y8/w1107-h626-no/2014-11-15%2B06.45.15.jpg

So, set the glazebuster into operation & whizzed it up & down the barrels a few times.
https://lh4.googleusercontent.com/-EnXt3Uy81v4/VIv02lP5HrI/AAAAAAAARWA/ZWmmo26JjOM/w354-h626-no/2014-11-17%2B18.35.47.jpg

https://lh4.googleusercontent.com/-02jp9U-hgq4/VIv04ywMSNI/AAAAAAAARWI/VKQAAkg27eg/w354-h626-no/2014-11-17%2B18.37.16.jpg

& started to replace the barrels.
https://lh3.googleusercontent.com/-UDQ7B3FBXnA/VIv08IccunI/AAAAAAAARWQ/KzwC6qhNTHw/w354-h626-no/2014-11-17%2B19.37.05.jpg

Now it was time for the fun. I bought a Valve spring compressor to make the job easier & also some valve grinding paste & tool for the job.

https://lh4.googleusercontent.com/-ptsCVTjMojc/VIv0-qJhuYI/AAAAAAAARWY/90QDscvGOjM/w354-h626-no/2014-11-19%2B18.31.03.jpg

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/t31.0-8/s960x960/10830526_10205307612309272_1119382747329183629_o.j pg

Time to fit the head back on. This turned out to be a lot harder than it coming off. Part of the frame seemed to be in the way, so needed some serious coaxing with a very large screwdriver, hammer & a lot of swear words. I did it in the end though. When I was refitting the cams i noticed that the rev counter drive was in a bad way, so knicked the one off my spare motor that was under the bench.
https://lh3.googleusercontent.com/-Fgf4leamkXY/VIv0YivLxyI/AAAAAAAARUo/3WJOeB4Bwh0/w1107-h626-no/2014-11-13%2B20.10.04.jpg

I had replaced all of the old valve guide oil seals which was a fiddly job in itself, but would be worthwhile in the end.
It was time to refit the head, reset the valve clearances & timing, then tighten everything up
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/t31.0-8/s960x960/10830678_10205311270600727_7982410090475712941_o.j pg

https://scontent-b-lhr.xx.fbcdn.net/hphotos-xfp1/t31.0-8/p417x417/10608647_10205337873145774_7751839138666668571_o.j pg

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10801550_10205337872545759_6288012193731441237_n.j pg?oh=c94ba763a6925dd9aae2d636868b910c&oe=5542E0A8

I refitted the carbs & tried her out to see if my work was a success, or whether it would go bang lol. She runs! & quite sweetly, but again, I was gutted, she still smokes :(
8nZVyzicX_A

Now, what I'm hoping is that it's the residual oil from me taking it to pieces & coating things with oil as I rebuilt it. If not, then I am going to be doing some serious head scratching because I haven't got a clue what it is.

I've also taken the carbs off because I found it difficult to have a mess with the mixture screws. The 2 outer screws are solid, so that's another thing I need to fix. The wonders of playing with a 30 odd year old bike :confused:
So, this is where I'm up to at the moment. I have a smoky engine & siezed mixture screws & have lost my mojo slightly. That is 1 good thing about rebuilding your own project, you can leave it for another day when you feel in the mood....... Watch this space :)

[andrewsmith]

Col a friends vtr did exactly the same thing and it was a case of the head bedding in, took about 2k before it started to settle

[squirrel_hunter]

Hopefully it is just from the build and that smoke will sort itself out. But might be worth doing a compression/ leak down test to see if there is anything amiss. Interesting to see some stuff I've not tried before with the heads.

[mister c]

Col a friends vtr did exactly the same thing and it was a case of the head bedding in, took about 2k before it started to settle
I'll get back into it shortly. A mate has offered me his trade plates to take it for a blast, but need a chain & sprocket kit 1st. It can wait till after Christmas now.
Hopefully it is just from the build and that smoke will sort itself out. But might be worth doing a compression/ leak down test to see if there is anything amiss. Interesting to see some stuff I've not tried before with the heads.
If I'm honest, I kept putting it off because the thought of it scared me to death, but once I got into the mindset that it was 4 individual engines, I was fine. The camchain was probably the hardest part of the job

[Jayneflakes]

Damn good stuff, an interesting read as always. I do love these build threads.

Sorry to read about your oil smoke in the exhaust. One question, did you replace the piston rings? I did wonder if they had worn into the old bore before you polished it a little and that could be your cause as they no longer fit as tightly? Just an idea, but I am not a mechanic, merely a keen tinkerer.

The wife's old bike used to smoke no matter what she did. Thankfully she herself has now given up smoking, so that is an improvement! ;-)

Good luck getting it sorted

[Teejayexc]

The wife used to smoke no matter what she did. Thankfully she herself has now given up smoking, so that is an improvement! ;-)



Did you get her rebored, or just get her valves lapped? :smt025

[maviczap]

I'd guess the timing was out because someone had attempted to do the camchain tensioner?

I used to have the Honda workshop manual, but I think I gave it to the new owner when I sold it

Still an interesting thread so far Col

[suzukigt380paul]

I'll get back into it shortly. A mate has offered me his trade plates to take it for a blast, but need a chain & sprocket kit 1st. It can wait till after Christmas now.

If I'm honest, I kept putting it off because the thought of it scared me to death, but once I got into the mindset that it was 4 individual engines, I was fine. The camchain was probably the hardest part of the jobyour problem may lay as others have said,with using old rings in a bore you have deglazed,it is possible you may have gone over the top with the bore deglazing,did you use the fine grade stones and use plenty of lube!

[mister c]

your problem may lay as others have said,with using old rings in a bore you have deglazed,it is possible you may have gone over the top with the bore deglazing,did you use the fine grade stones and use plenty of lube!
If you have a look at the picture with the piston ring in the bore, there is hardly any gap between the rings. I checked the tolerance before & after I deglazed the barrels & they were well within the given parameters. I don't think that anybody would be THAT stupid to try & hone so much out.

[suzukigt380paul]

If you have a look at the picture with the piston ring in the bore, there is hardly any gap between the rings. I checked the tolerance before & after I deglazed the barrels & they were well within the given parameters. I don't think that anybody would be THAT stupid to try & hone so much out.like i say old rings with deglazed bore,what do the oil control rings look like in the bore

[mister c]

Rings look ok, so am going to try running her for a while to see if it clears. A small amount of oil can produce a lot of smoke. The engine was only running for about 3 - 4 minutes.
Had another problem which needed attention. The mixture screws on the outer carbs were siezed, so thought I would remove the carbs & sort them out. 1 came out no problem, the other was completely solid. The screw head snapped off, so I tried hacksawing a new slot, screw snapped :(. Bought a stud extractor kit, but it still didn't shift. Luckily I have another bank of carbs, set set to stripping & cleaning them out.
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-19194032_zpsf432d0c7.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-19194032_zpsf432d0c7.jpg.html)

http://i5.photobucket.com/albums/y177/croozenooze/2014-12-19194037_zps8d6bf971.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-19194037_zps8d6bf971.jpg.html)

http://i5.photobucket.com/albums/y177/croozenooze/2014-12-19195351_zps28727ebd.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-19195351_zps28727ebd.jpg.html)

http://i5.photobucket.com/albums/y177/croozenooze/2014-12-19202938_zps002a7e66.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-19202938_zps002a7e66.jpg.html)

I'll do some rebuilding this afternoon when I get home from work

[Geodude]

Bugger, there's always a stubborn one. Good job you have an aladdin's shed of bits, keep up the good work :)

[Jayneflakes]

Hmmmmm, who needs Nigella...

Keep up the good work, it makes for a most enjoyable read.

:D

[mister c]

Right, so I took the other bank of carbs apart. Some parts were in great condition, others were a bit of a mess.
Top item is the choke actuator arm from the donor carbs. Underneath is off the old set.
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-20151802_zps147161bf.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-20151802_zps147161bf.jpg.html)

One choke plunger was completely siezed into the body, so had to get a little brutal. She came out eventually with a lot of WD40 & wiggling with a pair of pliers.
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-20152228_zps3d222d63.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-20152228_zps3d222d63.jpg.html)

Cleaned everything up & reassembled.
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-20153138_zps8536551a.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-20153138_zps8536551a.jpg.html)

I fitted them to the bike & fired it up. Runs not too bad, smoked quite a bit on start up, but ran it for about 10 minutes, looks like the smoke is disappearing, which is a good sign. Going to start taking the fuel tank apart next & get rid of the old fuel.

[Sir Trev]

This is a cracking thread Col. You have way more patience than I have!

[mister c]

I just love taking things to bits, cleaning them & putting it back together again :) Whether it works afterwards is always the trump card though lol.
So, onto the fuel tank. It does need spraying, but that can wait until all the other jobs are complete. The fuel gauge didn't work, so it was time to remove the sender unit. I emptied all of the 5 year old fuel & soaked the nuts in trusty WD40 & left them for a bit. They came out, no problem at all.
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-21152550_zps11b8d354.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-21152550_zps11b8d354.jpg.html)

I also removed the fuel tap to make sure it was clean before refitting.
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-21152739_zps11483835.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-21152739_zps11483835.jpg.html)

Out came the sender unit & plugged it into the wiring loom. It still didn't work, so checked for voltage to the plug. I didn't have any, so cleaned the electrical contacts &, hey presto, it works! :)
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-21154401_zps1086ea41.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-21154401_zps1086ea41.jpg.html)

There is a lot of rusty water in the tank, so I'll flush that out.
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-21153515_zps70ee32fd.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-21153515_zps70ee32fd.jpg.html)

I then stripped the fuel tap right down & cleaned it up
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-21155246_zpsf708c76a.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-21155246_zpsf708c76a.jpg.html)

I took all of the metal parts & cleaned them up on my new bench grinder, boy that saves some time :)
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-21160121_zpse22a3d05.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-21160121_zpse22a3d05.jpg.html)

Good as new
http://i5.photobucket.com/albums/y177/croozenooze/2014-12-21160925_zps0521bd1a.jpg (http://s5.photobucket.com/user/croozenooze/media/2014-12-21160925_zps0521bd1a.jpg.html)

[maviczap]

Luvely jubbly

[mister c]

I've left the CBX alone for a couple of days, but, seeing as the soaps were on last night, I went outside. I put the sender unit & fuel tap back onto the tank & put some fresh petrol in it. Time to try the engine on cleaned carbs & tank & more importantly, new fuel. She fired up no problem & the smoke has lessened greatly. She runs quite smoothly too, even though I haven't balanced the carbs yet. I'm very pleased now because that means I don't have to strip it down again :) I've now fitted the Airbox, so I'm now back to the same stage as I was about a month ago.

c57ZLDIpGxU