Topic: My 2nd CB650 project... This one with a build thread.

[onepieceatatime]

I got another project to work on. It will probably be a slow moving project, but i will post updates as they happen. I have almost finished my 1980 CB650C, so now on to a 1980 CB650 I plan to try to do a build thread on this one, since I did most of the other one before I found this forum, and didn't take any pictures while working on it. I already have a spare engine, and a 1980 CB650 as a parts bike that I picked up for $50 and in about a week I will have 1981 CB650 parts bike that I got for $30.
Here are the photos of what I am starting with.





Plus it came with all of these parts. If the engine on the new parts bike is any good, I'll probably keep the CV carbs to go with it, otherwise they will be added to a pile of parts that I am going to list on e-bay at some point.



This headlight will be going on the bike, with a H4 halogen conversion kit like the custom got.




2 spare wiring harnesses


Harley exhaust 

The ram needs replaced on this, but it was thrown in with the parts too.

Oh, and the tires are new.

The spare speedometer drive is slightly different than stock, it uses a clip to hold the cable on, not a screw.
Also the spare fuse holder is slightly different, the choke cable mount hole is open on the side instead of the top.

[onepieceatatime]

I forgot to take a picture of the seat... It has been recovered, but is in very good condition.

[onepieceatatime]

When I pull off the rusted out right side exhaust, and replace it with a used one off my parts bike, do the copper washers have to be replaced as well, or are they re-useable?
Thanks

[goldarrow]

nice finds, cheap bike! to start with is always nice. 

you could probably reuse them if they're still in good shape but they are pretty cheap on feebay, so i would just replace them.

[onepieceatatime]

nice finds, cheap bike! to start with is always nice. 

you could probably reuse them if they're still in good shape but they are pretty cheap on feebay, so i would just replace them.

Ok, thanks.
I figured they should be replaced, but I was not sure. I have not had the engine or exhaust off my first project bike, but other than that I pretty much rebuilt it from the ground up. I figured on maybe next winter pulling the engine from that one, sandblasting and re-painting the frame.
I don't think I am going to go that far on this one. Probably just put it back together with the correct parts and use it that way.

[JimJamerino]

Way cool to see another 650 project going. I have a 1980 CB650C and a 1980 CB650 as well. It seems they're mostly the same, but there are enough differences to cause a headache if you're not paying attention.

BTW, just where in the world do you snap up 2 parts bikes for $80?!

[onepieceatatime]

The $50 one was on ebay last summer in Pottstown, PA. The $30 one was on ebay in Leesburg, VA this month. I drove to get the first one, about 2 hours each way. I had a co-worker who lives near Leesburg pick up the other one. He is dropping it off at work for me on Monday.

[onepieceatatime]

I have noticed several small differences between the 2 models. Most apparent is the wheels, exhaust, and logos, but the forks are about 2 inches longer on the custom, black plastic chainguard and headlight bucket on the standard, chrome on the custom and the master brake cylinder is slightly different also. I put a standard model headlight bucket on the custom (not a big fan of chrome), but have an original if I decide to go back to it.

[onepieceatatime]

So I got a chance to do some work on it today.
First I pulled the front wheel off because the it had the wrong rotor and the caliper wouldn't fit.




Then off with that headlight.



At this point, I am thinking "Look at this mess, no wonder the PO included 2 wiring harnesses in the parts box".

And there went the "Waterproofing" for the wires, revealing 

and once all that extra stuff was gone,

http://i.imgur.com/ptJci.jpg
He didn't hack up the original harness after all.

And what CB650 is complete with out its 30A wire?


The forks came off due to extreme amounts of oil getting past the seals.
And the clutch lever has a severe bend. I don't think I would be able to use it.

But I have one from the first parts bike


I figure I am going to have to rebuild the master brake cylinder, so lets take it apart.

I think I'll rebuild the one off the parts bike instead of the one with the screw broken off.

[onepieceatatime]

I picked up my parts bike today. Once taken apart, it fit nicely into my Ford Escort. 

[goldarrow]

i wish things are as easy as just "pick up the parts bike" here in SoCal area

if you're ever taking apart your 650 sohc/4 engine, i might be interested in a few parts, tach drive with cable, tach gauge, and camshaft.   my 550 camshaft is pitted

[onepieceatatime]

The parts bike did not have a Tach on it. I do however have a spare cam and tach drive gear that I have been thinking about putting up for sale.

[JimJamerino]

The $50 one was on ebay last summer in Pottstown, PA. The $30 one was on ebay in Leesburg, VA this month. I drove to get the first one, about 2 hours each way. I had a co-worker who lives near Leesburg pick up the other one. He is dropping it off at work for me on Monday.

I have a hard enough time not buying every bike I want just trolling Craigslist, so it's probably a good thing that I don't lurk ebay.  I think my wife would shoot me if I put another non-running motorcycle in the garage.  If it were running, that would be a different story... but good luck picking up a runner/rider for $30!

[goldarrow]

Once you decide, add me to top of your list? 

[onepieceatatime]

Once you decide, add me to top of your list? 

If I do, you have first choice.

[onepieceatatime]

The $50 one was on ebay last summer in Pottstown, PA. The $30 one was on ebay in Leesburg, VA this month. I drove to get the first one, about 2 hours each way. I had a co-worker who lives near Leesburg pick up the other one. He is dropping it off at work for me on Monday.

I have a hard enough time not buying every bike I want just trolling Craigslist, so it's probably a good thing that I don't lurk ebay.  I think my wife would shoot me if I put another non-running motorcycle in the garage.  If it were running, that would be a different story... but good luck picking up a runner/rider for $30!

A bit of clarification...
I have a 1980 CB650C I bought years ago for $400, then bought an untitled parts bike last year for $50. The engine was blown on that parts bike. I then got a good spare engine. Now this project is another $400 bike (1980 CB650). Then I bought a $30 non-runnning untitled parts bike (it is an '81). The engine turns over, the tank is solid but full of rust and has a couple of dents. The forks look very good, but are soft. The carb rack has been picked apart, but I have a carb rack that will fit it. I think this could be a good spare engine too. I also have a big pile of spare parts from other sources.

[onepieceatatime]

I compared the rotor I pulled off the front wheel with the one on the parts bike I got today. They are the same size, so I guess the wheel that was on the bike with the new tire was off a 1981 cb650. The forks off the parts bike are in very good condition compared to the 2 sets of 1980 cb650 forks I have. I think I am going to use them on the bike instead of the 1980 version. I compared part numbers and they both take the same caliper. I will have to swap back to the larger rotor. I will probably rebuild these forks too, even though they do not appear to be leaking. The dust seals are even in good condition, soft and not cracked like the ones on the 4 sets of 1980 forks I have.

[goldarrow]

i wouldn't worry about those tires and wheels yet.  i would focus on fire, fuel, and air and other major components to get the bike running first.  i'm sure you already know 

[onepieceatatime]

i wouldn't worry about those tires and wheels yet.  i would focus on fire, fuel, and air and other major components to get the bike running first.  i'm sure you already know 

First, I think I need to worry about a battery.    Once I have that, then the fuel, fire, air. Since I have the wheels rotors, etc already, that is what I was working with (one of the reasons I took on another CB650 project). When it comes to spending money though, the getting it running will be the priority.

I had the other one running 2 years ago, but then the choke cable connection to the carbs broke and the battery failed. I replaced that junk piece of plastic, and put the carbs back on it, but have not gotten a battery for it yet. Besides that, it needs the tank to be sealed, which I will be doing next week. Then I should have a runner and can take all the time playing with this one that I want.

Before I hook the tank and battery to that one, I may try to fire this one up though, just to see if it will run. Carbs have been cleaned (by PO) but I do not think a bench sync was done.

[goldarrow]

[/quote]
First, I think I need to worry about a battery.    Once I have that, then the fuel, fire, air. Since I have the wheels rotors, etc already, that is what I was working with (one of the reasons I took on another CB650 project). When it comes to spending money though, the getting it running will be the priority.

I had the other one running 2 years ago, but then the choke cable connection to the carbs broke and the battery failed. I replaced that junk piece of plastic, and put the carbs back on it, but have not gotten a battery for it yet. Besides that, it needs the tank to be sealed, which I will be doing next week. Then I should have a runner and can take all the time playing with this one that I want.

Before I hook the tank and battery to that one, I may try to fire this one up though, just to see if it will run. Carbs have been cleaned (by PO) but I do not think a bench sync was done.
[/quote]

there are several ways to clean out the tank.  if money is the issue, you could try the cheap and effective way Electrolysis.  Or expensive way, the high way, using Evaporust which seems to work well.

[onepieceatatime]

I got a chance to do a little work on the bike today. I rebuilt the master brake cylinder, put in tapered steering stem bearings, and started to rebuild the forks. The forks are all cleaned up, and the new oil seals are in, but I am still waiting on the oil seal retaining rings, and dust seals. Once I get those, I will re-fill the forks, and re-assemble the front end. I bought all of the correct headlight parts that were missing, and the bike will look correct when I get it back together. I also bought an '81 CB650 headlight so I can have H4 bulbs instead of sealed beam. I have sealed the tanks for both bikes with Caswell's epoxy sealer, but spilled some lacquer thinner on the rattle can black paint job that was on this project. Needless to say it looks terrible, so it will be sandblasted and repainted.

[onepieceatatime]

I finished the fork rebuild. Re-assembled the front end and put in a 1981 H4 headlight. I also lubed the cables.

I think I also figured out why the PO couldn't get it to run...
The spark plug boots were all loose on the wires. I bumped one and it fell right off, so I checked the rest of them.

Still to do on this bike:
new brake line
clean carbs
finish sandblasting and paint tank
check/adjust chain
check rear brake shoes
check/ adjust cam chain
check/adjust valves
put in battery and check out electronics
title transfer/ insurance/ registration


I got these off of craigslist, they came from a 1981 CB650. I am going to paint them black, but I have not decided which bike to put them on yet.

[goldarrow]

I think I also figured out why the PO couldn't get it to run...
The spark plug boots were all loose on the wires. I bumped one and it fell right off, so I checked the rest of them.

That actually happened to me also with my cm400 months ago.  Spark plugs were loose, and also didnt realized that i was really low on fuel.

Simple little thing makes a big difference.

[onepieceatatime]

Got started on cleaning carbs last night for both bikes.
The carbs for the Custom is finished and all passages clear. I put them on the bike this morning, and got it started for the first time in several years. Sounds like the cam chain needs adjusted, and while I am at it, the valve clearances will be adjusted too. Carbs need another look too, #1 and #2 float bowls overflowed.

Carbs for the standard still need work too. All passages are clear except for 2 of the accelerator pump openings, #1 and #3.

I'll post some pictures later from the spare set of carbs. They need a ton more work before the floats can even be taken out. There was about 1/8 inch of lacquer in them. I did get the main jets and the float bowls cleaned through.

[onepieceatatime]

Last year I bought a spare rack of carbs for the CB650 from Ebay. I opened the box to be sure nothing was visibly broken, and was greeted by stale gas smell and wet packing material. I put them on the shelf as they were not really needed. I decided it was time to clean them along with the other 2 sets, and this is what I found.








I put 2 of the bowls in a good solvent  and 2 into Simple green to compare results.
These 2 were in the solvent.

And these 2 in the simple green.


So the solvent ones went into the simple green too along with the main jets and emulsion tubes(which I forgot to take a picture of)


The passages and slow jets still need to be cleaned, as well as the floats. I need to soak them just to free up the floats for removal.
More to follow next week.

[goldarrow]

Simplegreen or pine-sol always works great

[onepieceatatime]

I did a little more on that nasty set of carbs today.
I had to use a hammer and punch to get the float pins out. Then pliers to pull the float needles. I pulled the slow jets using vice grips.
I am still not ready to disassemble this rack. probably during the next cleaning session.
Here is the rack after sitting in simple green for 10 hours. Only 3 of the 4 would fit into the container I had.




The 3 floats that soaked and the 1 that did not:


The little bits (I kept them separated by carb)


and the slow jets


It is obvious that much work remains to be done. After I have gotten most of the crud out using simple green, I will finish the clean up with carb cleaner.