2017-04-07 08:01:28 : should be committed...
»
Find bdeed64d1aad514261a815d62f14fc54e7a80c6a on GitHub.
should be committed...
: Fall ride outside of Boston.
{% mark excerpt %}
Obeying a widely-known primordial need within the soul, I [-was compelled to acquire-]{+acquired+} a 1972 Honda motorcycle in the summer of 2013. [-It's-]{+It was (then)+} a 41 year-old machine and requires continuous attention. That is part of the fun. This is mostly a place for me to keep track of notes.
{% endmark %}
I've found great satisfaction in working on it: tracing down corroded electrical connections, adjusting the [-timing, changing-]{+timing & valves, rebuilding+} the [-tires. I lean back, hands dabbed with oil and inhale-]{+cylinders—a nice change of pace from+} the [-petroleum's intoxicating bouquet... Why,-]{+technological-computer arts where+} I [-just might write [a book](http://en.wikipedia.org/wiki/Zen_and_the_Art_of_Motorcycle_Maintenance) about it.[^zen-1]-]{+usually find myself.+}
## Projects
- [Right-Hand Switch Rebuild](right-hand-switch)
- [Starter Solenoid Rebuild](starter-solenoid)
{+- [Top-End Rebuild](top-end-rebuild)+}
- [Clutch Cleanup ](clutch)
{+- [1979 Honda CB750F Super Sport](super-sport)+}
## Maintenance Table
I've been working my way down this, little by little. It's pretty handy.
{{ macros.render_figure('<a href="http://www.flickr.com/photos/samjacoby/10817763986/" title="HSM500550_9 by s_jacoby, on Flickr"><img src="http://farm8.staticflickr.com/7405/10817763986_cd48417a9f.jpg" width="368" height="500" alt="HSM500550_9"></a>', "From when charts were king.") }}
## [-Components-]{+Parts+}
{+-+} Front Tire: Bridgestone Spitfire S11, 100/90 *(Fall 2013)*
{+-+} Rear Tire: Bridgestone Spitfire S11, 110/90 *(Fall 2013)*
{+- Carbs: 627B Keihin (#100 mains, #40 pilots — OEM replacements). +}
{+- Aftermarket 4-into-1, ceramic-coated black (Evid Mad Headers, NYS)+}
{+- Points: New TEC OEM points (replacing Diachi)+}
{+- APE HD Cylinder Studs+}
{+- OEM Honda Head Gasket+}
{+- Vesrah Gasket Kit+}
{+- Stainless hex hardware throughout+}
{+# Compression Check+}
{+cyl 1: 120+}
{+cyl 2: 120+}
{+cyl 3: 130+}
{+cyl 4: 130+}
{#
## Replacing Fork Seals
@@ -71,11 +89,20 @@ August 2014 | Oil Filter | Replaced
August 2014 | Oil Pump | Replace oil pump seals
September 2014 | Oil Switch | Replaced leaking oil pressure switch
September 2014 | Front Caliper | Replace piston seal
January [-2014-]{+2015+} | Motor | Removed. Whew!
February [-2014-]{+2015+} | Motor | Disassembled Head
April [-2014-]{+2015+} | Motor | Removed cylinder studs (ouch)
April [-2014-]{+2015+} | Tank | Sealed w/ Eastman 2K Clearcoat
May [-2014-]{+2015+} | Motor | Valves reground, new seats cut (MAS Machine, Iowa City
{+May 2015 | Motor | Painted & reassembled top-end w/ new Versah gaskets +}
{+February 2016 | Chassis | Tapered steering bearings (previous owner installed) +}
{+February 2016 | Baggage | Machined new +}
{+March 2016 | Fuel System | Broke down carburetors & cleaned; replaced all rubbers; cleaned OEM brass +}
{+April 2016 | Shocks | Replaced stock shocks w/ new HAGONs (200lb load) +}
{+April 2016 | Fairing | Installed Vetter Windjammer +}
{+April 2016 | Electric | Replaced dash lights with LEDs +}
{+May 2016 | Fuel System | Pipes ceramic coated (Evil Mad Headers, New York) +}
{+June 2016 | Fuel System | Rejetting 627B carbs w/ Keihin #40 pilots+}
## Resources
2015-08-06 11:23:11 : Refactoring motorcycle pages.
»
Find 3fcf19a9cf2d8b3b3d1a6dd02e6dc05ea1a7d5d8 on GitHub.
Refactoring motorcycle pages.
---
title: Motorcycles
summary: In which I discover what everyone else already knew
date: [-2013-10-21-]{+2014-10-21+} 23:30:01
thumbnail: motorcycle.jpg
track: True
---
[-{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/10402047085/in/set-72157636792385405/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Matching colors (October 2013)") }}-]{++}
{+: Fall ride outside of Boston.+}
{% mark excerpt %}
Obeying a widely-known primordial need within the soul, I was compelled to acquire a 1972 Honda motorcycle in the summer of [-2013.[^soul]-]{+2013.+} It's a 41 year-old machine and requires continuous attention. That is part of the fun. This is mostly a place for me to keep track of notes.
{% endmark %}
I've found great satisfaction in working on it: tracing down corroded electrical connections, adjusting the timing, changing the tires. I lean back, hands dabbed with oil and inhale the petroleum's intoxicating bouquet... Why, I just might write [a book](http://en.wikipedia.org/wiki/Zen_and_the_Art_of_Motorcycle_Maintenance) about it.[^zen-1]
{+## Projects+}
{+- [Right-Hand Switch Rebuild](right-hand-switch)+}
{+- [Starter Solenoid Rebuild](starter-solenoid)+}
{+- [Clutch Cleanup ](clutch)+}
## Maintenance Table
I've been working my way down this, little by little. It's pretty handy.
{{ macros.render_figure('<a href="http://www.flickr.com/photos/samjacoby/10817763986/" title="HSM500550_9 by s_jacoby, on Flickr"><img src="http://farm8.staticflickr.com/7405/10817763986_cd48417a9f.jpg" width="368" height="500" alt="HSM500550_9"></a>', "From when charts were king.") }}
## [-Right-Hand Switch Rebuild-]
[-For awhile I've had terrible problems with the electrics (particular the starter), so I decided to restore that whole pathway, from the right-hand switch (home to the ignition button) on down to the starter solenoid (which feeds the starter motor) on to the starter itself. -]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449722364/in/set-72157636792385405/player/" width="500" height="375" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "My shattered starter button. A pretty common problem on these bikes, apparently.")}}-]
[-There are some great write-ups in the SOHC4 forums on how to rebuild the bars where the switch lives--so I'll leave most of it to the experts. The toughest part of the whole job was simply removing the switch in the first place. Some of the screws were pretty badly rusted and stripped (my fault), so I had to work some magic with a screw extractor. Those things have saved me twice now.-]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12450255044/in/set-72157636792385405/player/" width="480" height="640" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Harbor Freight's finest at work and play. This was really hard.")}}-]
[-Removing the screw. A real pain, as I didn't have a vise or anything to hold the bars steady, so they were wiggling all over the place. Kind've had to brace it and get at it from beneath--and then hammer upwards into myself. -]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449907513/in/set-72157636792385405/player/" width="500" height="375" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Triumph.")}}-]
[-The screws were mangled, but rather than getting myself to Ace and figuring out what the threads were to replace, so I ordered replacement screws direct from Bike Bandit. It's insane that this stuff is still stocked, in little individually-wrapped plastic bags with part numbers no less.-]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449225635/in/set-72157636792385405/player/" width="375" height="500" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Removed from the bars and disassembled.")}}-]
[-Here's everything pulled off and disassembled. You can see some of the remaining shreds of PVC tubing that the cable ran through (I replaced it with heatshrink).-]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449241225/in/set-72157636792385405/player/" width="375" height="500" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "")}}-]
[-I re-soldered the leads to the phenolic plate that backs against the kill switch. See that helping hand? It's helping. -]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449754934/in/set-72157636792385405/player/" width="500" height="204" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "")}}-]
[-A dab of grease helps keep the spring-loaded bearing that keeps pressure on the grooved plate in place (I don't know any of the right terms.)-]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449244235/in/set-72157636792385405/player/" width="375" height="500" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Fascinating.")}}-]
[-I polished the tongued contacts that control the high and low beams on the headlight. -]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449748804/in/set-72157636792385405/player/" width="375" height="500" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "I did the heatshrink over the stove (not pictured for professionalism)")}}-]
[-I also cleaned up the connectors to the starter switch (I bought new OEM parts for that, as well as 3D-printed some examples.)-]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449256575/in/set-72157636792385405/player/" width="500" height="375" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "")}}-]
[-And then screwed the whole beast back together. -]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449772924/in/set-72157636792385405/player/" width="500" height="381" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Don't mind the drop shadow...")}}-]
[-The final cleaned and re-assembled right-hand switch (RHS) for a 1972 CB500. -]
[-## Starter Solenoid-]
[-Online, a number of people suggest checking out your starter solenoid to make sure that it's routing current to the starter, correctly.-]
[-{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449415763/player/" width="500" height="391" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "CB500 starter solenoid, opened up.")}}-]
[-My solenoid wasn't all that dirty and it seemed to be working correctly. I could hear the click of it firing when I hit the ignition--but I didn't know much about how it worked or whether the contacts themselves were making a good enough connection.-]
[-I cleaned it up some and then ran some tests with a bench-top supply at work. Draws a fair bit of current to trigger, which makes sense. It's a beefy little unit. Of course, I also looked on Ebay where new replacement solenoids are being sold for like $8, but restoring them is more fun. -]
[-<iframe width="560" height="315" src="//www.youtube.com/embed/5i1YHoF_J6s?rel=0" frameborder="0" allowfullscreen></iframe>-]
[-## Clutch-]
[-I've started tackling the clutch in earnest. They're notorious in CB500s and Honda overhauled them in the 550. Mine has been giving me trouble on-and-off since I picked it up, but recently, it's started to grow worse. It's close to impossible to hit neutral while hot -- which is pretty standard fare -- but more troubling, the clutch hasn't been disengaging while in first, so I've got to keep the engine revved to prevent it from bogging down. One hand on the throttle, one on the brake -- not a good situation. -]
[-I started by breaking into the parts bike, just to get a sense of how the pieces fit together -- which has been useful. It's a bit nerve-wracking to begin wrenching without having any idea what's in there (though I have the manuel), so it's nice to have something to play with. Tackling the clutch has been a chore. The old gasket is just about fused to the crankcase, and it's taking a couple of soaks with various solvents and a razorblade to clean it off. Nice and shiny now, though. -]
[-I checked out the clutch plates from both machines -- neither were so amazing. I checked the steel plates for warping against a glass plate and a feeler gauge. They mostly seemed OK, actually, though according to many reports, that's unlikely. The friction plates showed a bit more wear, but they also weren't warped and basically good enough to use. More concerning was that their cork pattern was clearly not stock, nor was it any of the other well-known cork facings (square, etc.) I deglazed (I hope), the steel plates with some fine sandpaper. I also measured the springs, which looked basically fine. -]
[-{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/13806512005/player/" width="600" height="800" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Clutch basket laid bare.") }}-]
[-{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/13806618593/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Mystery friction plates.")}}-]
[-{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/13806883674/player/" width="600" height="800" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Measuring over here.")}}-]
[-{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/13806544755/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "In theory, these are fine.")}}-]
[-I picked up some synthetic Mobile grease for no reason other than it was the most expensive, and I figured why-the-hell-not. Turned out to be red, which I don't like. -]
[-The lifter assembly and bearing went in pretty smoothly. I found a new pushrod on Ebay -- technically belongs to a CB450, but it seems to fit in there pretty nicely (same 8mm diameter), and it's i good shape. Getting an OEM clutch cable was a good idea too. A clutch cable was one of the first things that I bought when I got the bike. Now, the better part of a year later, I know that it's some non-OEM junk that's not even close to the right length.-]
[-{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/15414325736/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Beneath the clutch basket.") }}-]
[-{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/15250835787/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Replacement lifter (from a CB450)") }}-]
[-{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/15434191861/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Left to right: crap, old OEM, and new OEM") }}-]
[-The whole thing came back together well enough, and though I wouldn't exactly call my clutch smooth-shifting (the plates probably do need to be replaced), but it's working well enough for now.-]{+Components+}
{+Front Tire: Bridgestone Spitfire S11, 100/90 *(Fall 2013)*+}
{+Rear Tire: Bridgestone Spitfire S11, 110/90 *(Fall 2013)*+}
{#
## Replacing Fork Seals
@@ -157,4 +85,3 @@ May 2014 | Motor | Valves reground, new seats cut (MAS Machine, Iowa City
- [New England Honda Guys](http://nehondaguys.info/)
[^zen-1]: Never read it. Hear it's not really about motorcycles. Update 05/27/2015. Read it. Is kind've about motorcycles.
[-[^soul]: See *Easy Rider*. -]
2015-06-26 10:22:48 : Moved motorcycles page to new location (and lost change history).
»
Find dbdc004ad63fa8e5c9c4400b8655334b5d0c30f2 on GitHub.
Moved motorcycles page to new location (and lost change history).
- [Honda CB500 Manuals](http://www.sohc4.net/cb500-manuals/ ) (Courtesy of SOHC4)
- [New England Honda Guys](http://nehondaguys.info/)
[-[zen-1]:-]{+[^zen-1]:+} Never read it. Hear it's not really about motorcycles. Update 05/27/2015. Read it. Is kind've about motorcycles.
[^soul]: See *Easy Rider*.
2015-06-02 19:42:11 : Various tweaks.
»
Find ecb0bb8e7e8a0ac43f9fe423eeab47d49c192fe1 on GitHub.
Various tweaks.
@@ -0,0 +1,160 @@
{+---+}
{+title: Motorcycles +}
{+summary: In which I discover what everyone else already knew +}
{+date: 2013-10-21 23:30:01+}
{+thumbnail: motorcycle.jpg +}
{+track: True+}
{+---+}
{+{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/10402047085/in/set-72157636792385405/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Matching colors (October 2013)") }}+}
{+{% mark excerpt %}+}
{+Obeying a widely-known primordial need within the soul, I was compelled to acquire a 1972 Honda motorcycle in the summer of 2013.[^soul] It's a 41 year-old machine and requires continuous attention. That is part of the fun. This is mostly a place for me to keep track of notes. +}
{+{% endmark %}+}
{+I've found great satisfaction in working on it: tracing down corroded electrical connections, adjusting the timing, changing the tires. I lean back, hands dabbed with oil and inhale the petroleum's intoxicating bouquet... Why, I just might write [a book](http://en.wikipedia.org/wiki/Zen_and_the_Art_of_Motorcycle_Maintenance) about it.[^zen-1]+}
{+## Maintenance Table+}
{+I've been working my way down this, little by little. It's pretty handy. +}
{+{{ macros.render_figure('<a href="http://www.flickr.com/photos/samjacoby/10817763986/" title="HSM500550_9 by s_jacoby, on Flickr"><img src="http://farm8.staticflickr.com/7405/10817763986_cd48417a9f.jpg" width="368" height="500" alt="HSM500550_9"></a>', "From when charts were king.") }}+}
{+## Right-Hand Switch Rebuild+}
{+For awhile I've had terrible problems with the electrics (particular the starter), so I decided to restore that whole pathway, from the right-hand switch (home to the ignition button) on down to the starter solenoid (which feeds the starter motor) on to the starter itself. +}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449722364/in/set-72157636792385405/player/" width="500" height="375" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "My shattered starter button. A pretty common problem on these bikes, apparently.")}}+}
{+There are some great write-ups in the SOHC4 forums on how to rebuild the bars where the switch lives--so I'll leave most of it to the experts. The toughest part of the whole job was simply removing the switch in the first place. Some of the screws were pretty badly rusted and stripped (my fault), so I had to work some magic with a screw extractor. Those things have saved me twice now.+}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12450255044/in/set-72157636792385405/player/" width="480" height="640" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Harbor Freight's finest at work and play. This was really hard.")}}+}
{+Removing the screw. A real pain, as I didn't have a vise or anything to hold the bars steady, so they were wiggling all over the place. Kind've had to brace it and get at it from beneath--and then hammer upwards into myself. +}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449907513/in/set-72157636792385405/player/" width="500" height="375" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Triumph.")}}+}
{+The screws were mangled, but rather than getting myself to Ace and figuring out what the threads were to replace, so I ordered replacement screws direct from Bike Bandit. It's insane that this stuff is still stocked, in little individually-wrapped plastic bags with part numbers no less.+}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449225635/in/set-72157636792385405/player/" width="375" height="500" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Removed from the bars and disassembled.")}}+}
{+Here's everything pulled off and disassembled. You can see some of the remaining shreds of PVC tubing that the cable ran through (I replaced it with heatshrink).+}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449241225/in/set-72157636792385405/player/" width="375" height="500" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "")}}+}
{+I re-soldered the leads to the phenolic plate that backs against the kill switch. See that helping hand? It's helping. +}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449754934/in/set-72157636792385405/player/" width="500" height="204" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "")}}+}
{+A dab of grease helps keep the spring-loaded bearing that keeps pressure on the grooved plate in place (I don't know any of the right terms.)+}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449244235/in/set-72157636792385405/player/" width="375" height="500" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Fascinating.")}}+}
{+I polished the tongued contacts that control the high and low beams on the headlight. +}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449748804/in/set-72157636792385405/player/" width="375" height="500" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "I did the heatshrink over the stove (not pictured for professionalism)")}}+}
{+I also cleaned up the connectors to the starter switch (I bought new OEM parts for that, as well as 3D-printed some examples.)+}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449256575/in/set-72157636792385405/player/" width="500" height="375" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "")}}+}
{+And then screwed the whole beast back together. +}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449772924/in/set-72157636792385405/player/" width="500" height="381" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Don't mind the drop shadow...")}}+}
{+The final cleaned and re-assembled right-hand switch (RHS) for a 1972 CB500. +}
{+## Starter Solenoid+}
{+Online, a number of people suggest checking out your starter solenoid to make sure that it's routing current to the starter, correctly.+}
{+{{ macros.render_figure('<iframe src="http://www.flickr.com/photos/samjacoby/12449415763/player/" width="500" height="391" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "CB500 starter solenoid, opened up.")}}+}
{+My solenoid wasn't all that dirty and it seemed to be working correctly. I could hear the click of it firing when I hit the ignition--but I didn't know much about how it worked or whether the contacts themselves were making a good enough connection.+}
{+I cleaned it up some and then ran some tests with a bench-top supply at work. Draws a fair bit of current to trigger, which makes sense. It's a beefy little unit. Of course, I also looked on Ebay where new replacement solenoids are being sold for like $8, but restoring them is more fun. +}
{+<iframe width="560" height="315" src="//www.youtube.com/embed/5i1YHoF_J6s?rel=0" frameborder="0" allowfullscreen></iframe>+}
{+## Clutch+}
{+I've started tackling the clutch in earnest. They're notorious in CB500s and Honda overhauled them in the 550. Mine has been giving me trouble on-and-off since I picked it up, but recently, it's started to grow worse. It's close to impossible to hit neutral while hot -- which is pretty standard fare -- but more troubling, the clutch hasn't been disengaging while in first, so I've got to keep the engine revved to prevent it from bogging down. One hand on the throttle, one on the brake -- not a good situation. +}
{+I started by breaking into the parts bike, just to get a sense of how the pieces fit together -- which has been useful. It's a bit nerve-wracking to begin wrenching without having any idea what's in there (though I have the manuel), so it's nice to have something to play with. Tackling the clutch has been a chore. The old gasket is just about fused to the crankcase, and it's taking a couple of soaks with various solvents and a razorblade to clean it off. Nice and shiny now, though. +}
{+I checked out the clutch plates from both machines -- neither were so amazing. I checked the steel plates for warping against a glass plate and a feeler gauge. They mostly seemed OK, actually, though according to many reports, that's unlikely. The friction plates showed a bit more wear, but they also weren't warped and basically good enough to use. More concerning was that their cork pattern was clearly not stock, nor was it any of the other well-known cork facings (square, etc.) I deglazed (I hope), the steel plates with some fine sandpaper. I also measured the springs, which looked basically fine. +}
{+{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/13806512005/player/" width="600" height="800" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Clutch basket laid bare.") }}+}
{+{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/13806618593/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Mystery friction plates.")}}+}
{+{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/13806883674/player/" width="600" height="800" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Measuring over here.")}}+}
{+{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/13806544755/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "In theory, these are fine.")}}+}
{+I picked up some synthetic Mobile grease for no reason other than it was the most expensive, and I figured why-the-hell-not. Turned out to be red, which I don't like. +}
{+The lifter assembly and bearing went in pretty smoothly. I found a new pushrod on Ebay -- technically belongs to a CB450, but it seems to fit in there pretty nicely (same 8mm diameter), and it's i good shape. Getting an OEM clutch cable was a good idea too. A clutch cable was one of the first things that I bought when I got the bike. Now, the better part of a year later, I know that it's some non-OEM junk that's not even close to the right length.+}
{+{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/15414325736/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Beneath the clutch basket.") }}+}
{+{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/15250835787/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Replacement lifter (from a CB450)") }}+}
{+{{ macros.render_figure('<iframe src="https://www.flickr.com/photos/samjacoby/15434191861/player/" width="800" height="600" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>', "Left to right: crap, old OEM, and new OEM") }}+}
{+The whole thing came back together well enough, and though I wouldn't exactly call my clutch smooth-shifting (the plates probably do need to be replaced), but it's working well enough for now. +}
{+{# +}
{+## Replacing Fork Seals+}
{+I wanted to get this done before I took the ride out to Iowa City. I've had a very slight leak on my front fork seals--not much, but enough to show an issue. Of greater concern are persistent handling issues I've had since I picked up the bike in the summer of 2013. I noticed it early on -- on one of the very first rides I took, in fact -- a pronounced wobble when deaccellerating from the 40s or so. It turns out that this is a fairly common issue, usually resolved by replacing the original head bearings with a tapered set. New fork oil could only help, though I think I've got deeper-seated issues there than just that. +}
{+## Oil Pump Seals+}
{+## Oil Switch+}
{+I've been trying to track down an oil leak in my left crankcase -- it's never been an enormous amount of oil, not enough to stop me riding, but a pain nonetheless. I've done the little tricks with the baby powder, and I thought it was the oilpan seal for awhile. +}
{+I've been having a long-standing leak +}
{+#}+}
{+## Work Log+}
{+I decided I should be keeping a dated worklog -- it's just a useful thing to do. I've been doing it by hand, but what else is the internet for? +}
{+Date | Item | Work+}
{+---|---|---+}
{+July 2013 | Oil | Changed+}
{+July 2013 | Oil filter | Replaced+}
{+July 2013 | Clutch | Clutch cover opened, cleaned, clutch adjusted+}
{+August 2013 | Petcock | Fuel filter screen checked+}
{+August 2013 | Fuel lines | Gas line replaced (with 5.5mm original) +}
{+Septemer 2013 | Tires | Replaced tires (Bridgestone S11), professionally-mounted & balanced+}
{+November 2013 | Spark plugs | Replaced original plugs with new NGK 12mm D7EA; new boots as well +}
{+November 2013 | Contact points | Checked & adjusted +}
{+February 2014 | Cam chain | Adjusted +}
{+February 2014 | Valves | Checked & adjusted+}
{+March 2014 | Petcock | Rebuilt and cleaned (again). Shouldn't be leaking anymore.+}
{+March 2014 | Airbox | Cover added from parts bike+}
{+March 2014 | Hardbags | Added a pair of white Shoei's+}
{+April 2014 | Oil | Changed, Castrol 10W-40+}
{+April 2014 | Seals | Replaced right-crank gasket+}
{+April 2014 | Clutch | Checked clutch plates for warping, wear+}
{+April 2014 | Clutch | Replaced clutch cable & lifter rod.+}
{+April 2014 | Ignition | Rebuilt key assembly +}
{+June 2014 | Fork | Replaced fork seals & changed fork oil +}
{+August 2014 | Oil | Changed +}
{+August 2014 | Oil Filter | Replaced +}
{+August 2014 | Oil Pump | Replace oil pump seals+}
{+September 2014 | Oil Switch | Replaced leaking oil pressure switch +}
{+September 2014 | Front Caliper | Replace piston seal +}
{+January 2014 | Motor | Removed. Whew! +}
{+February 2014 | Motor | Disassembled Head +}
{+April 2014 | Motor | Removed cylinder studs (ouch) +}
{+April 2014 | Tank | Sealed w/ Eastman 2K Clearcoat +}
{+May 2014 | Motor | Valves reground, new seats cut (MAS Machine, Iowa City +}
{+## Resources+}
{+- [SOHC4 Forums](http://forums.sohc4.com)+}
{+- [CB500 Clymer Manual](http://www.amazon.com/Cb350-550Cc-1971-1978-Clymer-Motorcycle-Manuals/dp/0892876530/ref=sr_1_1?s=books&ie=UTF8&qid=1383324794&sr=1-1&keywords=cb500+clymer)+}
{+- [Honda CB500 Manuals](http://www.sohc4.net/cb500-manuals/ ) (Courtesy of SOHC4)+}
{+- [New England Honda Guys](http://nehondaguys.info/)+}
{+[zen-1]: Never read it. Hear it's not really about motorcycles. Update 05/27/2015. Read it. Is kind've about motorcycles.+}
{+[^soul]: See *Easy Rider*.+}
