Author Topic: fmctm1sw '83 GL650 Interstate (Read 17610 times)

fmctm1sw · « **on:** December 21, 2013, 05:33:54 PM »

original discussion thread: http://forums.sohc4.net/index.php?topic=131548.0

This is going to take a while but no better time than the present to start a thread I guess. Quick summary of some other posting I've made. The oil has gotten water or antifreeze in it and it makes a squealing sound like a pig when you try to crank it. I took the starter motor out and it spun up quietly. So, I'm guessing the squeal is coming from inside the motor. I looked at the carbs today and they had water in them too. I was also met with another surprise. The head of the fuel mixture screw was snapped off! I tried slotting it with a dremel but the head continued to come apart. I ended up drilling it out and forcing the mix screw out through the tiny hole in the carb throat. It looks like I'll be ok once I get another fuel screw. Engine will need to come apart though...

fmctm1sw · « **Reply #1 on:** December 25, 2013, 04:01:43 PM »

I got the motor out today. I found some wiring shenanigans on the wire leading to the rectifier but other than that it came out pretty much as planned. The one small exception being the short drop on its side after I forgot about the clutch cable. I drained more of that nasty oil/water out of it. Kind of looks like someone poured cappuccino in it. I'm going to look at the rod and crank bearings before I sink money into a gasket set or anything.

seanbarney41 · « **Reply #2 on:** December 25, 2013, 06:55:47 PM »

now that you have the motor out

...did you give any attention to the starter clutch?...that's probably what was squealing

fmctm1sw · « **Reply #3 on:** December 26, 2013, 09:06:54 AM »

Quote from: seanbarney41 on December 25, 2013, 06:55:47 PM

now that you have the motor out ...did you give any attention to the starter clutch?...that's probably what was squealing

I don't have the rear cover off it yet but it's all being torn down. Hopefully, the main and rod bearings aren't toast and I can just clean that sludge out of it and put it back together. I may completely tear it down and have the frame powercoated too. I've never had a CX/GL this far apart so I'm taking lots of pictures

MoMo · « **Reply #4 on:** December 26, 2013, 11:53:09 AM »

water pump seal is a notorious weak point on the 500/650 motors. There is a step by step thread somewhere in internet space on using a Yamaha pump seal to replace the Honda. I have a 500I-love it, just needs the extra 150cc you have....Larry

fmctm1sw · « **Reply #5 on:** December 26, 2013, 06:15:35 PM »

Quote from: MoMo on December 26, 2013, 11:53:09 AM

water pump seal is a notorious weak point on the 500/650 motors. There is a step by step thread somewhere in internet space on using a Yamaha pump seal to replace the Honda. I have a 500I-love it, just needs the extra 150cc you have....Larry

Larry, yeah I picked up that Yamaha seal idea over on the CX/GL forums. I did the one in the CX500 I had that way. Didn't need to take the motor out either. This time, I'll have the motor out anyway but that seal is way cheaper too.

I'd like to report some good news today.... but I don't have any. Well, ok, the pistons aren't seized and the transmission spins freely. Outside of that, I took the clutch basket and oil pump out today. Big mess all over the place. I was actually interested in seeing what the oil filter looked like when I took the housing off. Nope, no filter. We don't need no stinking oil filters! The pictures tell the story. I'm pretty sure the clutch basket is assembled wrong, there are two steel plates back to back and the oil pump chain is way too loose but that's the least of my worries right now.

fmctm1sw · « **Reply #6 on:** December 28, 2013, 05:05:39 PM »

Quote from: seanbarney41 on December 25, 2013, 06:55:47 PM

now that you have the motor out ...did you give any attention to the starter clutch?...that's probably what was squealing

I got this all apart today except for a couple small snags. I can't get the camshaft out. I need a 27mm deep socket to get the nut off. And that starter clutch, I need a T40 torx bit to get the starter clutch out. It looks like someone tried to get it aprt because one of the torx bolts is a little stripped. Also, there is a gouge on the cover of it and it doesn't seem like all the parts are there comparing it to my parts book. I'll make sure I didn't drop them somewhere but I've been real careful tearing this down. So yeah, that was definitely screwed up. The good news is the crankshaft bearings looked good and I think the connecting rod bearings are ok too. If I could find new ones I might just replace them but they're listed as obsolete. The bad news is the camshaft. I can see the lobes are chewed up. I'm glad I tore it all the way down, that milky stuff is all through the engine. The cam chain slipper and tensioner didn't look like it had any wear on it at all. The shift forks have a lot of life left in them too.

fmctm1sw · « **Reply #7 on:** December 28, 2013, 05:18:32 PM »

camshaft lobe... Hopefully I can find another one or maybe one from a GL500 will work...

fmctm1sw · « **Reply #8 on:** January 11, 2014, 06:25:06 PM »

I've been working steadily on this for a few weeks. I got the motor all torn down and have been cleaning up the motor parts. I found out my starter clutch was toast. I pondered in this thread: http://forums.sohc4.net/index.php?topic=133241.0 whether or not there were supposed to be holes in it and it turn out there are. Mine seem somewhat mangled though. Through a completely lucky bounce, I came across a NOS starter clutch. As I was looking through google images to look at those holes, I found an auction image. When I went to the auction it said the seller was unavailable and not processing orders and I should watch it and bid later. Well... I went ahead and made an offer anyway and bought it. I wasn't able to get it to come up in any ebay search but it's mine now. I did tell the seller about it. I even found a NOS gear to go along with it. I already have all new parts for the starter clutch coming too. Another rude surprise awaited me with the oil pump. Look at it... ruined. Every time I turn around something on this bike is ruined. I got the clutch cover and rear cover cleaned up pretty well. I'm going to clean and measure all the other engine parts as I reassemble it. The alternator was filthy and had gouges where the starter clutch rollers made contact. I'm still working on smoothing them out. From what I've been reading these starter clutches are weak spots on the GL650s.

fmctm1sw · « **Reply #9 on:** January 11, 2014, 06:44:43 PM »

These engine covers aren't anything to write home about but that nasty milky oil was all through them. Much cleaner now. I used gasoline to clean out the oil passage and I unbolted the twisty tube that leads to the oil filter and cleaned that too.

fmctm1sw · « **Reply #10 on:** January 14, 2014, 05:10:05 PM »

I ordered a set of piston rings last night and this morning I took the engine block to a rebuilder to hone it. I showed him my camshaft and he agreed it was toast. I'm going to look for new rockers as well. He's also going to work on a tiny nick I had in the crankshaft.

fmctm1sw · « **Reply #11 on:** January 29, 2014, 01:49:00 PM »

Did some work on the oil pumps that I have. I decided to try to smooth them out with a rotary tool. Tolerances didn't seem to change after I got done. I'll decide which of the two is better and go with it. Motor still out at the shop...

I've also been soaking rusty stuff in Evaporust. It did a great job on my water pump tubes and impeller and I got the pump body and other stuff in there now.

fmctm1sw · « **Reply #12 on:** February 02, 2014, 05:16:42 PM »

I'm taking my time on this one. I had the rocker shafts out today and the oil passages were gunked up in them too. A photo of one that has soaked and one that has not.

fmctm1sw · « **Reply #13 on:** February 15, 2014, 08:18:21 AM »

I got my block back from the shop yesterday and I decided to throw a quick coat of paint on the engine. Today, I plan on plastigaging the rod bearings. I also bought four new rocker arms and I found an outfit in California that can restore the camshaft (www.webcamshafts.com).

fmctm1sw · « **Reply #14 on:** February 15, 2014, 04:19:56 PM »

And they're... GOOD! Now, I have to figure out the best way to paint these motor emblems.

MoMo · « **Reply #15 on:** February 15, 2014, 05:29:48 PM »

Sharpie oil pens are great for the emblems...Larry

fmctm1sw · « **Reply #16 on:** February 15, 2014, 06:09:32 PM »

Quote from: MoMo on February 15, 2014, 05:29:48 PM

Sharpie oil pens are great for the emblems...Larry

Noted, thanks!

fmctm1sw · « **Reply #17 on:** February 17, 2014, 04:41:43 PM »

The painting was going great until my sharpie exploded. I ended up blobbing pools of paint in the HONDA part and spreading it out. Looks ok from a distance though.

MoMo · « **Reply #18 on:** February 17, 2014, 05:22:31 PM »

Quote from: fmctm1sw on February 17, 2014, 04:41:43 PM

The painting was going great until my sharpie exploded. I ended up blobbing pools of paint in the HONDA part and spreading it out. Looks ok from a distance though.

How in the heck did that happen?...Larry

fmctm1sw · « **Reply #19 on:** February 23, 2014, 05:45:40 PM »

Quote from: MoMo on February 17, 2014, 05:22:31 PM

Quote from: fmctm1sw on February 17, 2014, 04:41:43 PM
The painting was going great until my sharpie exploded. I ended up blobbing pools of paint in the HONDA part and spreading it out. Looks ok from a distance though.

How in the heck did that happen?...Larry

It appears the paint normally travels through the tip. Mine went around around the tip so every once in a while a big blob would come out. The larger one worked better.

I got the valves out of the heads today. One of them was stuck pretty good. They all measured out in serviceable limits. I sprayed them with brake cleaner and the they got a 10 hour or so dip in the Evaporust.

fmctm1sw · « **Reply #20 on:** March 09, 2014, 06:14:36 PM »

It feels good to start putting this together. I got the crankshaft cap back on with an assist from the CX500 forum guys after a dodgy parts book drawing of the crankshaft side washers. I got one piston in as well after a struggle. Pistons go in from the top, I'm accustomed to pushing them up from the bottom. I sent my camshaft out last Friday for restoration.

fmctm1sw · « **Reply #21 on:** March 16, 2014, 04:45:42 PM »

Got a lot of work done over the past few days. The second piston is in and I lapped the valves and reinstalled them into the heads. The transmission is in and I went to work on the clutch basket. The friction disks are pretty much shot and it took me what seemed like hours to file all the grooves out of the clutch basket fingers. The oil pump pumps well but the chain is stretched so I'll look for a new one. The next challenge I think will be the rocker arms. They look nearly identical but are different. I still have the news one in the bags so I can use the part numbers. I had a small scare when the clutch housing gears were misaligned but I realized they could be straightened back out.

fmctm1sw · « **Reply #22 on:** June 10, 2014, 04:53:48 PM »

I've been slowly chipping away at this. I had some issues getting the valve timing right at first so it was a good thing I turned it with my hands before I just hooked it up to a battery

Next, I'll blast and paint the radiator and engine hangers. Then the engine will be complete. Then I need to decide if I'm going to take the rest of the bike apart and blast and paint. Putting this motor into a ratty bike would be like putting a silk hat on a pig...

fmctm1sw · « **Reply #23 on:** July 16, 2014, 06:29:54 PM »

It's been a while for this. I ended up having the frame, swingarm, and other stuff powdercoated. I couldn't put that nice motor into a ratty frame. Right now, I struggling to get the races out of the swingarm and I'm putting tapered roller bearings in the steering stem too. I need to set the ignition timing and add oil to the motor. The monoshock hardware on this bike was trashed too. I ended up getting two sets from ebay and made one good one.

grcamna2 · « **Reply #24 on:** July 16, 2014, 07:01:26 PM »

That's a Nice bike fmctm1sw, I had an 82' Silverwing but like Larry said I really wanted that extra 150cc's. Who put all that water into your motor ??

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Author Topic: fmctm1sw '83 GL650 Interstate (Read 17610 times)