Topic: 1977 CB750k restore project

[dgilling]

I went to change my sprockets, chain, front disk, and brake lines, and now I have the bike taken down completely to frame and motor.  I've always wanted to restore as much as possible and I guess now is the time.  I'm not looking for perfection, just better and I want to keep it running as good as it does.  The bike is rusting out in lot of places, electrical was in pretty bad shape.  I would like to do small things to the engine, but I don't want to mess with it too much.  I did the carbs a while back and don't plan on messing with them.

I bought the bike 8 years ago for $300 and rode it almost every day when I lived in California.  I've since moved to Colorado and being the winters are much longer she doesn't see as much action.  I wish I would have started this project in the winter. 

I hope to clean it up pretty good but I don't want it to become a money pit.  I plan to replace the important things and do most of the work myself.  I can't decide if I want to get the frame powder coated or just try and paint it myself.  I feel like sandblasting would save me a ton of cleaning time and if it's at the shop getting sand blasted I might as well get it powder coated, along with the wheels and other parts. 

Here is my list.  Let me know if i'm missing an important one.   
To do:
Rear wheel
   -Remove old rusted spokes
   -Order new spokes
   -Powder coat wheels
   -Polish hubs or paint black??
   -Order/Install new bearings
   -Lace/true rim
   -Mount/balance tire
Front wheel
   -Remove old rusted spokes
   -Order new spokes
   -Powder coat wheels
   -Polish hubs or paint black??
   -Order/Install new bearings
   -Lace/true rim
   -Mount/balance tire
Front/rear Brake
   -Order new Godferry Rotor
   -Order new sling shot brake lines
   -Rebuild caliper (maybe) needs some new screws for sure.
   -Clean/polish rear brake pedal
   -Clean/install rear brake light switch
Frame
   -Clean and powder coat or paint
   -Clean/Install inner fender
   -Remove rear fender rust and possible paint black, considering bobbing the fender
Body
   -Remove cap and petcock from tank, strip paint and prep, recreate the skull stencil
   -Replace Headlight fork ears with new ones or polish and remove rust on old ones
   -Strip/prep headlight bucket
   -Clean/polish fenders and misc shiny parts
   -Order new turn signals
   -Order new Cateye taillight
   -Order new brighter headlight
Suspension
   -Replace front fork seals
   -Paint lowers
   -replace springs with progressive springs
   -stanchions have damage, which damages the seal, replace or repair
   -Polish up rear springs
Engine
   -Clean
   -Paint?
   -Polish covers and shiny bits
   -Paint black background on alternator cover, possible replace alternator cover.
   -Replace valve cover gasket
   -Inspect/replace cam chain tensioner
   -New Header gaskets
Airbox
   -Replace case
   -replace rubber boots, but they're so damn expensive!!
Gauges
   -Replace with new smaller ones, they speedometer doesn't work anyways
Electrical
   -Clean and replace as necessary

[SOHC4 Cafe Racer Fan]

A restoration is inherently a money pit, but the end product is priceless.  It's not a financial investment -- it's a fun investment.

[dgilling]

These are my original photos of the bike when I got it 8 years ago.  The skull will stay, i'll need to recreate the stencil somehow.  I thought for sure i'd go all flat black but I see some gloss black and I'm starting to like it.  Not sure what to do now.  I painted the headers and they stayed black for a long time but is starting to fade again.  I've also dented the gauges and the front fender.  Other than that it looks pretty much the same. 

[dgilling]

This restore might come with a lot of dumb questions so please bare with me.  I've done a lot of searching on the forum to try and find answers but sometimes it's easier to just ask and get a quick answer. 

How do I decide on what to paint and what to powder coat?  I'm getting close to having all the parts removed.  All that is left is the motor from the frame.  Then I need to make a decision on what to paint, powder coat, or clean up to shiny chrome again. 

Any one have suggestions on their favorite products and methods for removing rust from chrome?

I hope a lot of people subscribe to this restore because I'm going to need the help. 

[chewbacca5000]

Wow looks like a very ambitious project.  Be sure to take one major system at a time and you will be fine.  If you are looking for original color on the frame it is around 80 to 85 percent gloss.  Keep the pic coming.

[dgilling]

Thanks so much for the reply.  I hope to start cleaning tomorrow after I get the motor all the way out with a buddies help. 

I pulled the lowers off the forks tonight and removed the seals.  One was leaking.  The race has a pretty big gouge in it.  Should I try and file it smooth? 

It was tough to get the lower allen bolt out too.  The piece on the inside just kept spinning with the bolt, even with an impact wrench.  I head to create a wedge and hammer it down on it to hold it. 

Here are some of the parts I removed.  Any feedback is welcome and encouraged. 
Rust on Spokes.  Hoops actually look rust free. 




Dent in front fender, I want to modify this one to be smaller anyways. 




These pieces on the header just fell off when I removed them, and I think there's supposed to be a copper gasket in there but I see no evidence of one.  The fourth cylinder seemed to leak oil out the header gasket but i could never really tell for sure because of other leaks.


Brakes are going to need some new parts


Fuse Box.  Do you think this will clean up?  I looking to pinch pennies where ever I can.  Especially on something that is easy to replace down the road. 


Cb750k by dustygillingham, on Flickr

Battery must have leaked some acid
Cb750k by dustygillingham, on Flickr

I've never really known what this part on the bottom of the battery box is for.


Rust on bottom of the fender
[url=https://flic.kr/p/nvd7SK]

I'm pretty sure i want to replace these.  I have some from a 750 custom that look like the same part and are in a little better shape but I might just want to replace all together.
[url=https://flic.kr/p/nbWUfo]

Headlight box with the previous owners on/off switch. 


I'm probably just going to put these same shocks back on save the replace for another day when I recover from everything else.


Gauges will go, speedo didn't work anyways but I believe that's the original miles. 

[dgilling]

The bike feel over a in my garage a long time ago and cracked the alternator cover.  I JB welded it, and it held up for a long time.  Starting to flake now.  I want to just replace but holy cow those things are expensive.  Any ideas to repair?

[dgilling]

A good portion of battery acid leaked down here.  I'll make sure to install a proper drain hose!


Top of rear fender
[url=https://flic.kr/p/nt9rN8]

I did my best to take some pics of the exhaust.  Pretty messy.  I'm not even sure what it should look like on the inside.  Every valve doesn't look the same though. 
[url=https://flic.kr/p/nroQrU]

[url=https://flic.kr/p/nbWL3F]

[url=https://flic.kr/p/nbWWtG]

Notice the top of the spark plug.. Things are pretty white and corroded.  The actual electrode on the plugs looks pretty good though. 
[url=https://flic.kr/p/nvdabH]

[dgilling]

Should the shells be replaced? It looks like in this case the shells are in one piece. http://www.powersportsuperstore.com/Mac-4-Into-1-Canister-System-Black-201-2601-p/4156378.htm?Click=35177

Nice to know on the forks.  I was following the clymer manual.

Any ideas on the alternator cover?   

[dgilling]

I got the motor out tonight, but had a casualty.  I bent the engine bolt that connects to the pegs and mangled the threads on it, but motor is out and on to cleaning now!  I'm definitely going to have to come up with a more graceful way to mount the motor.  We had to wiggle and wobble that thing to get the frame off. 

Do I spend anytime cleaning something if I'm going to get it sand blasted anyways?  It seems like that would be a waste of time. 

[dgilling]

I was planning on having the following items media blasted (not sure which one) and powder coated a matte black finish. 
frame
swing arm
fork lowers
center stand
battery box
alternator cover
gear shift cover
valve cover
battery caliper
wheels
hubs

I planned on painting the following items:
Gas Tank
Fenders
side covers

[AintNoEasyWay]

Sweet. The skull logo is badass. Restoring a K7 as well. Subscribed.

[Chaser60]

Your call on budget with regard to PC.   If you want to save a little money, you will find that rustoleum products (in a gloss of to match your PC parts) will work out great for things like battery box, gage bracket, dummy lights housing, ignition bracket etc.   Any of the small, non outward or highly hidden parts can be rattle can painted.   Some folks have found PC guys that basically quote the big stuff and will toss in the little items for another small upcharge.   If you can find that, have them all done.   

As someone said above, the money just keeps flowing out.   I am past what I could ever get for this bike for sale, but when done, I will have a one of a kind bike that winds out to 10 grand on the tac for less than 5k.    Smiles per dollar spent will be very very high.

Cheers and good start.

[dgilling]

I just bought a sand blaster with soda conversion kit from harbor freight.  Everything for under $200.  I also started calling around about powder coating prices and some places are pretty reasonable for blasting and coating.  One guy quoted me $200 for frame, swing arm, and some extra small stuff. 

Should I just take the blaster back?  I still have to do the motor so I'm thinking i'll get my money out of it there.

The other problem is I need to build up a place in the garage to do the blasting.  Hmmmm?

 

[dgilling]

I don't have the best air compressor but according to the numbers it can manage the blaster. It seems like the $200 for the blaster would be better spent towards new parts. Especially if the shops around here are pretty reasonable.

I think ill return it and just try and manage without it.

My biggest concern is how do I clean in between the fins on the motor without a soda blaster?

[dgilling]

I've got elbows so this crap is going back to the store. I hope to get in some good cleaning sessions tomorrow.

Any good threads on cutting and modifing the front or rear fenders? I've looked around but didn't find much with details. I'm sure I will have more questions after tomorrow.

Thanks or the advice. Always appreciated.

[dgilling]

Well I didn't get much done this weekend considering I had to fix the lawn mower and mothers day.  I did accomplish some things though. 

I disassembled the brake caliper.  The hoses were cracked in multiple places and there was a ton of rust inside the caliper.  The brake fluid in the caliper looked like black sludge.  I'm so surprised that it actually stopped.  I also removed the first part of the engine.  Things don't look pretty in there.  I'm afraid to take off the rest. 

Notice the black sludge coming out of the caliper


This is about as clean as I could get it.  Do you think it's okay?  Can I replace just the o-ring?  I can only find the oring for sale with the piston, and I think my piston is still good.  I also need a new hard pipe for the brake line.  I can't seem to find that either. 



Oh, boy... looks like a mess.  Bolts were rusted pretty good. 


Does this Race come out before powder coat?  Will I need to remove this I'm i'm putting all balls bearings in there?


Is this salvageable or will I need new fork tubes?  Doesn't seem like it will buff out.


Last question is do i remove the old bearings from the swing arm before powder coat?  What's the best method to remove those? 

[dgilling]

I found the o-ring here http://www.partzilla.com/parts/search/Honda/Motorcycle/1977/CB750K+A/FRONT+BRAKE+CALIPER/parts.html#uloc25

But there are two part numbers listed.  Which one do I need?

[edwardmorris]

Well I didn't get much done this weekend considering I had to fix the lawn mower and mothers day............

That was exactly my weekend lol.

Everything that Calj said, plus you may need to polish the caliper bore manually with super fine grit sanding paper. The groove of the caliper where the gasket goes it what is critical when it comes to cleaning. Low speed wire wheel on a dremel is generally sufficient to get it spotless.

[edwardmorris]

Last question is do i remove the old bearings from the swing arm before powder coat?  What's the best method to remove those?

You mean bushings? Uncle Terrence did the lowers recently, check it out here http://forums.sohc4.net/index.php?topic=61168.msg1544752#msg1544752

There are other ways too, search on these forums, mayble look into the CB750K3F project for more ideas on the main bushings..

[dgilling]

Dang it! i already order from sling shot and missed the memo on the forum discount.  Oh well. 

I worked on cleaning the piston a little last night and i the rust seemed to clean up pretty good.  I'm pretty sure it would work with a new o-ring.  I'll probably stick with the better safe than sorry approach though and just replace. 

How do you remove the bearing races from the steering tube?  are they just pressed in?  they kind of look threaded but I don't see a way to grab them to unthread.   

Thanks for the help again as always. 

[edwardmorris]

Dang it! i already order from sling shot and missed the memo on the forum discount.  Oh well. 

I worked on cleaning the piston a little last night and i the rust seemed to clean up pretty good.  I'm pretty sure it would work with a new o-ring.  I'll probably stick with the better safe than sorry approach though and just replace. 

How do you remove the bearing races from the steering tube?  are they just pressed in?  they kind of look threaded but I don't see a way to grab them to unthread.   

Thanks for the help again as always.

You may be able to contact slingshot with your order number. I forget if the owner is a member here or not, but worth a try contacting them.

That bearing race looks different than what I hammered out of mine, so I'll let the experts weigh in on that one. For the stock ones, you can look at my build thread on how I managed to remove them safely, just to get an idea...

[SOHC4 Cafe Racer Fan]

A brass punch or drift. Pound the lower out from above, moving around the circumference as you go. Invert the frame and do the top from underneath.

If you are better with visuals, check out Dino's project build thread.  He has videos showing the steps.  I think episode 3 or 4 deals with steering and swingarm bearing removal and replacement.  http://forums.sohc4.net/index.php?topic=135688.0

[dgilling]

Tonight was a night of "try everything, accomplish nothing".  I tried to remove the plastic bushings from my swing arm.  Those suckers aren't budging.  I was about to cut them out but figured I'd ask first.  Any ideas?



The lower swing arm bearings are completely seized and won't spin at all. I didn't even try to take them out yet.  I'm sure that will be fun.


Once I moved on from that I tried to remove the front tire.  Also seemed basically impossible.  it's a tubless tire so the bead is just a much tighter fit.  I'm pretty sure I'm going to have to take it to the shop to get the tires removed. 

Once I moved on from that I started in on some of the wiring.  I struggled really bad with the tiny little screws inside the lever bodies, but eventually got them.  Then I dropped a ball bearing and spent 20 min on the floor.  I finally found it though. 



After that I started to clean up the rectifier, and I guess i'm not really sure what to do here.  I tried some electronic cleaner and a brass brush, but I was afraid to really get in there and clean.  I don't want to just replace it because they are really expensive.  Whats the best way to clean this guy up?  I took the center bolt out and it had a lot of rust and corrosion on it. 



I then moved on to the fuse box but realized that it was melted through on the bottom fuse.  I guess I'll just replace that one. 

[edwardmorris]

A lot of people have had good luck with what Calj just described for the lower bushings, simple DIY puller.

If you're looking at a full teardown and rebuild, consider getting a set of good JIS drivers, this will save you a lot of frustration and stripped screw heads. Gordon/ilbikes here sells a great JIS driver set along with an impacta, you may want to message him. He also has other custom tools you may need down the line (big JIS impact driver, rotor puller, frame kit etc.).

+1 on the Hondaman's upgraded fuse box, much easier to find blade fuses and easy to carry spares.