Topic: 1972 CB750 Four K2 -- Rebuilt to NEW OLD STOCK -- PIX ON PAGE 50

[edwardmorris]

Well, the brake is finally working at least when parked. Cleaned up the master, sooooooo glad I had it powder coated (Thanks Marc!) because this this was soaked in brake fluid when I rebuilt it a second time. Not a spot affected  But the caliper didn't fare as well, will need a touch up job around the bleeder.

Installed this pesky little rebound damper rubber.

Zinced up retainer for it, I'd have had it chromed along with the pivot bolt, but I didn't get the correct master until much later in my build (Thanks Nick!).

[edwardmorris]

New washers for the rear axle and swingarm pivot bolt, they were both missing on the bike.

Finished up with the drain hoses, gotta straighten the out some more. Redid the greasing on the swingarm following the steps described by Mark/Hondaman.

Cleaned and sealed up the valve train cover with White Diamond while I could still get to it easily.

[edwardmorris]

New hardware for the ignition bracket along with rezinced collar. This piece is how I met Billy B, he responded to my wanted ad when I was new

Added extra sheathing to the neutral switch wire as it takes so much crap from the chain.

Adjusted the throttle cables, then installed the Gordon Frame Kit  This is such a convenience, basically a requirement for these bikes, so if you're still debating, just get it!

[Restoration Fan]

I so love mornings when I get up and you have posted additions to this thread.  Watching this bike come back together is truly like watching time in reverse.  This bike is going to be a show piece, it's going to be so beautiful.

[Bill/BentON Racing]

 

[edwardmorris]

Thanks, I'm trying to go faster, but after all the love I've shown, she's being really mean to me

[edwardmorris]

Also, I'd like to thank Gordon, Dave Z, Jerry H and Bill Benton for their help with the front brake. I apologize for the inconvenience caused by my phone calls and texts, and I'm really grateful to know you all (and your numbers ). Special mention and thanks to Ron/MCRider, for helping me with a 10x faster rebuild of the master cyl the second time around.

[edwardmorris]

New K2 harness with Hondaman upgrades on flat blade connectors and conveniently grouped up wires (this was a nice surprise!). NOS ignition switch and harness bands A & B. Mark also made me the tail light sub harness!

NOS coils and boots, new plugs. Will get to the boots and installing them on the wires later, as right now I have no idea how to do that.

All new mounting hardware for the coils, except for the rezinced brackets.

[edwardmorris]

Ignition switch installed on the bracket, but the locking nut stands proud a few threads because of the washer behind it. Sits perfectly flush without the washer, but I'm assuming its there for a reason. Did I install this wrong and will it sit flush with the washer?

Kept postponing installing the counter sprocket, finally have it hanging in place with all new hardware, will need to torque it down when the chain is on and holding that thing steady. I plugged up the hole in the final drive shaft with a 3mm o-ring cut small length. The little rubber on the oiler plug is surprisingly pliable after all these years. Will tighten that down fully to avoid any and all chain oiling that way.

Was thrown off by how the retainer?? lines up at first, but figured that it rests in that small slot on the final shaft. Right???

[edwardmorris]

All new mounting hardware for the battery box along with reconditioned rubbers and rezinced collars. All new hardware for the tool tray and electrical panel.

[edwardmorris]

All NOS electrics acquired over the past (almost) two years calling various stealerships.

Installed with all new hardware, missing is the fuse box and battery positive cable which I have NOS too.

[edwardmorris]

This seat latch lock is how I met Nick/Tews19, and is also the very first item I acquired on these forums for this build.

Installed with new hardware, and I managed to coerce the bracket in place to accept the second bolt too

[evanphi]

That is a shiny looking electrical compartment!

[edwardmorris]

Had some time so worked on tying up the rear brake to have it in place to install the diamond chain. Man that chain was a pain to break down to size. So I had some trouble with the brake adjustment rod, checked in with Dave and realized I don't have the pivot aligned right, the vertical chunk needed to be ahead of the swingarm. Tried pushing till one of my fingers started to bleed, so I cheated. Pulled the whole thing off, compressed the spring in the bench vice, tied it up and installed it in place. After things lined up, I cut off the string and done!

All new hardware for the other end of the stay bar and adjusting rod, rezinced nut and spacer, rechromed pedal and its bolt and washer too.

All new brake switch, chromed adjusting bolt, spring. All installed.

[Davez134]

Looks right now. Tying up that spring is a great idea!!

[edwardmorris]

So, the obligatory one step back. Clutch cover had to come off to fix it. I had two gasket kits, one for each bike, and one of them came missing a clutch cover gasket.  I had to tear open the other one and use it on this. No spares now, so have to wait till the replacement gets here. Cleaned out the permatex and installed the clutch arm correctly.

[edwardmorris]

Chain guard turned out nice, love that that powder coat is on the inside and out very nicely. All new hardware and isntalled.

Before that, I cut the diamond chain to 102 links, washed out the factory lube with some mineral spirits and CRC, then lubed it up with some chain lube. Need to do some fine tuning and adjustments tomorrow.

[edwardmorris]

Front fender got all new hardware. Yamiya has a perfect kit for this assembled with genuine Honda hardware, but is missing the plastic inserts. Had to reuse the old ones. Installed but not tightened, will do the fork alignment tomorrow and loctite the fork lower clamps.

[edwardmorris]

Front forks aligned and everything torqued down, glad that part is done. Installed the spark plugs and boots onto the wires. The spark plug ends don't have those 8 shaped pieces on them that screw on top of the tail end. I suppose that's how the boots snap into place, but where do I get them from? What are they called? Do I need them?


Installed all new exhaust spigots and gaskets with new hardware. The screws felt like they bottomed out, as in they stopped going in past a certain point as opposed to progressively getting tighter. Is that normal or do I need to torque these down?

Yet another early K2, or at least a K2 odditiy, the "Sub Harness B" used with the turn signal buzzer. I couldn't find a replacement or a repop anywhere so I made my own! Mark/Hondaman had sent me a set of sample connectors when I had my charging coil wires, main harness etc. worked on. Had to make do with the crappy crimper but the connections are solid.

[Tews19]

A meal could be eaten off that clean engine! Great work.

[Davez134]

I can't wait to see this one done! Amazing detail!

[edwardmorris]

Thanks fellas, REALLY wanting to have this thing fired up, this damned clutch cover thing is such a bummer, can't do anything till the gasket gets here. Oh well, last orders of bidniz are electrical and exhaust. Will keep plugging away in the mean time.

Got my gauge harnesses resleeved and terminals refreshed. Rubbers reconditioned, and replated bands with a convenient hardware kit from ebay, seller assured me its all OE stuff and it looks like it.

NOS gauge bases came with the gauges from KC_Northstar here. Gauges and handlebar controls came from him, he saw my build thread, reached out and explained a whole bunch of subtle details of the early K2 and sold me the gauges, controls, seat (now sold) and few other goodies. I was brand new, and so elated how everyone was diving in from everywhere to help 

Installed, but when I tightened down the bands, the orientation went to the crapper  Will fix tomorrow 

[edwardmorris]

Oh, again, BIG BIG BIG THANKS to Jerry H on helping me with the gauges! He painted the outer housings and crimped the tough as hell rings for me (I'm sure he did more and didn't tell me). Also, couldn't have done them this well without Marcel; all new faces, new lenses the whole thing!

[evanphi]

Where did you get your Diamond chain? Local dealer? My local Honda/Harley doesn't carry Diamond! I will likely get it from Revzilla... http://www.revzilla.com/motorcycle/diamond-530-chain

[edwardmorris]

Where did you get your Diamond chain? Local dealer? My local Honda/Harley doesn't carry Diamond! I will likely get it from Revzilla... http://www.revzilla.com/motorcycle/diamond-530-chain

Amazon.

http://www.amazon.com/Diamond-Chain-530-XDL-Drive/dp/B000GTW3QO/ref=sr_1_1?ie=UTF8&qid=1433781902&sr=8-1&keywords=diamond+xdl&pebp=1433781905448&perid=0ERT41TESAMYKHWXBC67

Its pretty tough to cut the extra links, and you'll need to "press fit" the master link. I used a C-Clamp with a socket, worked well, neat trick from Bill Benton.