Topic: 1977 CB750 K7 /// Rebuild 2.0, Project Anna

[knottedknickers]

I haven't lived in Alberta for a while, but would Blackfoot Cycle have it (even though they don't carry Honda)? I don't much enjoy darkening the doors of the 'big box' bike stores--the parts guys looks down their noses at me when I say "1976"--but it might be worth a try.

[mkoski]

I'm not sure about blackfoot! Maybe I'll check them out if I get the chance. I typically avoid the 'big box' stores like you mentioned, they have not been kind or helpful in my experience and don't like to spend money there for that reason.

I popped open my rod bearings for inspection and it looks like I'll have to spend a few bucks on those, as I see they are all in pretty bad shape, which is pretty realistic considering I spun one of them due to lack of lubrication... Here they are with/without flash:

Cyl 4



Cyl 3 (no bearing)



Cyl 2



Cyl 1



I cleaned out the top case and have been adding in parts as they are cleaned and ready to be installed. Right now I'm waiting on oil seals for the shafts, gaskets and rod bearings. Looking pretty good to me thus far though!

[calj737]

Before I went 1 step further, I'd be thoroughly inspecting that motor for obstructions in the oil galleys, and the oil pump. That amount of wear is indicative of a system wide issue in my narrow opinion.

[mkoski]

She lost oil pressure (and all volume) due to a failed oil filter leaking heavily out of the front. No blockage was the cause of this but I also took the care to ensure everything is open with thorough pressure wash, degrease and clean. So that shouldn't be a concern but thanks for the advice!

[firebane]

I pulled the trigger on a bunch of parts. Thus far I have ordered all the engine seals (including the odd-sized '77 specific one) and a full set of gaskets including rubber pucks and exhaust copper-crush gaskets. Throttle cables (push and pull) were thrown in because mine were a bit sticky (and from '77). Honda seems to have all the bearings in stock so I have my mission set up for tonight... Inspect all bearings, determine what color bearings I need, and order them, alongside a new cam-chain tensioner, which is surprisingly in stock as well.

I'm going to be re-using the tension-bolts on the con rods, as I can't justify the tag for a new set of 8 of them, and I will also be trying to minimize the number of bearings I buy, as those suckers come out to be 32$ per pair of shells. If you multiply that across all the bearings it turns out that it's $$$. Either way though, I think my bottom-end will be a happy place for a long time anyways, as it's already been pretty bullet-proof for me up until late. This weekend I want to clean out the cases, clean all the parts and prep everything for re-assembly. Lot's of parts cleaner and degreasing in my future, I think. Anyone know a decent place to source 3-Bond / hondabond here in Alberta, Canada?

Fellow Alberta from Calgary here... and I honestly find that getting stuff from online is far better. VintageCB750 and 4into1 have been my go to places. Locally for me things are just silly expensive or difficult to find. I couldn't even get 5.5mm fuel line locally from Honda.

[EvLoutonian]

Did you get this all sorted in the end?

Following along on your thread and enjoyed the details (as my K7 project nears completion also)..
(on the other side, in Melbourne, Australia)

[mkoski]

So at least two years have passed since I last updated. When I last updated I had a grenadified engine (thanks chinese oil filter!) and a serious case of denial to myself on how viable the engine was to re-use. Since then I bought a "new" engine, threw it in and rode my CB750 for a couple thousand km's. Things were great! Except the "new" engine liked to pop outta first gear when any throttle whatsoever was applied! So that was no good!

Eventually I got a new project, then another one, then my CB was forgotten again and went all summer this year without being ridden. My two projects since my CB have been an XL600R and a KTM 450 EXC that is my most ridden bike now! I feel like I have matured a lot as a motorcycle restorer/fabricator/customizer and my work is of significantly better quality. It's work that I'm actually proud of now!

XL600R Before
https://imgur.com/VTLjvlT

XL600R After:
https://imgur.com/RFgzV13


KTM Before:
https://imgur.com/ZfZmFvL

After:
https://imgur.com/9xUsfIn


Having winter rolling in now, I decided my CB750 needed to have 1st gear fixed. And then I got carried away and decided to rebuild the whole bike, but this time do it right, make it perfect both functionally and aesthetically.

So I'm re-kindling my thread here to carry this thing through the finish line!

If you are just joining me, this is what the bike looked like in 2014, when I bought her!

https://imgur.com/YL2R0CB

And just this week before tear-down:
https://imgur.com/wHxubJm

[mkoski]

Now, into the meat of the project. Over the weekend I tore into the engine, split cases, did an inspection of everything and have sorted things out. Take a look at this shifting dog!

https://imgur.com/JERPk6n

It's worn into the 4th gear (which engages first) by quite a lot, no wonder that first wasnt happy to stay in. I'll pull the gear later and take a picture of that as well. Other than that, the bottom end was just gorgeous. Clean, in tolerance, very little wear. The primary chain tensioner is supple still (somehow) and everything looks good. I'm going to simply replace the tranny parts I need to and close it back up and get into the top end next.

https://imgur.com/5I47e80

Very happy to be back here and working on my CB again. This is a great community and I love reading everyone's projects! I have some fun ideas for this time around and cant wait to try em out!

[calj737]

Member Bill Benton can probably hook you up with new dogs.

[mkoski]

Member Bill Benton can probably hook you up with new dogs.

Thanks Cal! I sent him a message.

Turns out there is wear inside the groove of the shift drum on the right dog as well. The mating pins from 4th gear into 1st on the countershaft are really rounded off too from slipping out so often. Found a cheap parts engine in town so I might pick that up this weekend to open up in hopes of finding nice transmission bits. Probably worth the risk for an easy win with no shipping delays.

While the engine is pending I started working on the frame. Need to fix the rear shock mount tapped holes, install a frame kit for the cutout I have, install new bronze swingarm bushings and paint it! Should keep me busy until the the engine is ready to drop in when I get my parts sorted.

[calj737]

While the engine is pending I started working on the frame. Need to fix the rear shock mount tapped holes, install a frame kit for the cutout I have, install new bronze swingarm bushings and paint it! Should keep me busy until the the engine is ready to drop in when I get my parts sorted.

and after you finish all that tonight, what are you going to do tomorrow? 

[mkoski]

Hahah. My build pace has been really good lately! Partly from having a new shop (my work) that I can use and partly from better planning! That XL600R was built in 30 days, front to back, including the engine rebuild. Guess there are some advantages of being single and childless!

[mkoski]

Ended up fairly busy this weekend but managed to get a few key items accomplished! Picked up what might be the ugliest engine I have seen but I was hopeful that the transmission would be okay.

https://imgur.com/wzPadRU

As I started stripping it I saw that it had both had a valve meet a piston top and it had thrown a chain through the case, which broke several pieces off. The PO had repaired the massive hole with fibreglass! Never seen that before. I ended up getting extremely lucky though and found a full transmission set and forks in near perfect condition! Just a bit of dirt to clean off and then I'll be buttoning my case back together this week.

https://imgur.com/vYEEgTQ
https://imgur.com/dbEOOhf

Besides that I made a frame kit to reattach my cut section of frame and I also epoxy-painted the frame and swingarm a nice, even black. Didnt snap any pics but I will next time I'm working on er.

[mkoski]

Almost a month later! Jeeze! I have been crazy busy in the last while on not-my-CB750-things, which isnt ideal... But I ran across a really nice Bandit 650 for a low price so I fixed it up to make some money on it and I also ended up starting a custom-fit supercharger project for my car. Between that and work, time flies!

I have made some really great progress with my CB750 though! Old transmission - out. New transmission - in. Case put back together, all covers re-installed, engine painted, engine re-mounted to frame. Really really happy with how clean the engine came out to be!

https://imgur.com/ryfTtsZ

Going for brushed-aluminum look with a nice automotive clear-coat for the bits that arent black...

https://imgur.com/Mm3bz3c

And here's the final result!

https://imgur.com/Djy8KcG


Tonight I'm going to install my oil tank and fill er up. I'll cycle through with the kick-start I think until I have full circulation. Just want to ensure no leaks at this stage of the game. Then I'll be re-assembling the rear and front ends next!

[mkoski]

After finishing a DIY supercharger and with the approach of summer, I'm back on the CB750!

I have put together the rebuilt engine, installed the front and rear ends and now I'm into the rest of the mechanical and electrical. Here is how she currently sits:



I am registered for a garage-built show at the end of the month, so I have three weeks to a polished, completed motorcycle.

The major changes that I am going to be making are to the tank and seat, adding knee-dents and re-shaping the seat. Besides that I'm going for a better fit and finish this time around (a few years after my first build of this bike now!) and even splurged on those gorgeous cognito moto rearsets and new rear suspension (everyone was right about the ride quality of the Chinese RFY's)!

Nice to be back working on the CB!

[mkoski]

Spent some time this weekend on the bike, polished up the front caliper and clear-coated it, did the rear brake linkage in black, installed the electrical harness and started getting that going.

Looks like I'll have my headlight, turn signals, the stainless steel bolts for the entire bike and a few other finishing touches in this week. Hopefully I can get all the detail work done up by the weekend and then start on the body-work and paint for the seat, tank and side-covers! I'm excited to refine the profile of the motorcycle a bit more and make the seat something really comfy to be in. Right now it looks saggy and sad. Right now it's just sitting in place as I need to build a new seat pan out of aluminum.

Not a huge update but electrical is never a pleasure for me.

[mkoski]

Well this weekend was a good one (and a long one here in Canada). I spent a couple days in the shop and got to add a bunch of parts that came in. I mounted up my headlight ears, the headlight (with a nice LED H4 bulb), the exhaust went on, got the electrical system working, added some nice progressive-style LED turn signals, finished wiring up the alternator, ran a few more misc cables and (my favorite) got a wireless push-button ignition system running. I used to have RFID installed but it took up a lot of space and this solutions is much more elegant and functional. One button press on, bike is ready to go, one press, its all off and disabled. Simple latching relay system (20$) that leads into an automotive 12V relay (4$). Now I dont need a keyed ignition and it keeps everything sleek.



I also got lower rear suspension, so I dropped the front just over 0.5" to level it a bit. By my calculations this should ensure that the front wheel doesn't contact the headers at all. That's probably important...

The tank, seat and sidecovers will be re-done to give a betting riding position and updated paint, as the old stuff is all scratched up now. Besides that, I need to mount the speedo/gauge and make a seat pan. Last, I need to mount the rearsets when they come in. Then shes done and ready to ride once again! Very excited!

[mkoski]

Just a small question I wanted to ask you guys:

What is the most elegant way to attach cables to the lower forks? I used to use electrical tape with a zip tie over top but I think I have grown past that level of quality in my builds these days. I just need something secure, non-marking and low-profile for the front speedo cable and brake cable. Also my clutch cable I suppose!

On another note, just got my cognito moto rearsets. They are gorgeous! Almost cost as much as my bike when I first bought it hahah! Too excited.

[mkoski]

More progress updates! Things are flyin along! Good thing too, bike is due Friday for the show!

Rearsets, check:



LOVE these things. Smooth as hell, beautiful shift feel, perfectly positionable, gorgeous. Worth the money!

Front gauge, brakes, cable maangement and wiring: Check



Ended up running the clutch cable below the headlight, much straighter line and it's smooth as butter now.

Tail pan with under-side brake and signal lights: Check.



A paper template, a hacksaw, sandpaper, a few hours. Happy with it, fits great. My clearance to the brake light isnt quite enough but I'll set the rear end stiff for now until I have time to suck it up a bit higher into the underside of the pan.

Points set, valve lash set, final wiring connected and managed, quick carb cleanout, final bolt check through the bike annnnnd shes a runner!  Back to being the first kick engine she always has been for me! So excited! First gear feels very solid (transmission replaced due to it jumping out before) from a short indoor ride in the shop. It snowed 20cm this weekend in Calgary!

Tonight I am repainting the tank and side covers, starting on the seat template to carve it out.

Here's the design plan... A bit taller, farther forward (single-seat bike) to keep the visual weight of the bike even, build up the rear a bit and put the seated position into exactly where I actually sit.



Tuesday, finish and glass the seat. Apply my secret decal layout to the tank and covers.

Wednesday, finish the seat, sand, bondo, paint.

Thursday, if all is well, drink some beers! Maybe a once-over on the bike again, polish it up.

Friday, drop-off at the show!

A few minor odds and ends as well, registration, insurance, tail wiring, more cable management, charge the battery up and put a plate/tag bracket somewhere. The seat is top priority though!

[mkoski]

Two days remaining!

Side-cover and tank are painted. Just need a good polish to even out some orange-peel from the clearcoating.





Had to bondo the emblem-mounting points to keep it smooth all the way around. Had a couple small dings to fill as well.

Started the seat shaping process. Happy with how it has taken form thus far. Tonight I'll shape the front and blend it into the tank, then cover and fiberglass it for paint tomorrow. Need to adjust the seat length I currently have as well, as it's too long with the pushed-forward seat design I went with.




Friday I'll have final pictures with everything done up!

[mkoski]

Well, shes done! Again! Two frame up builds, one blown engine, one engine without first gear, another engine with a hole in the case to donate a transmission, a one or two casual hours in the shop  and my bike is back to being ready to ride every weekend all weekend for the summer!

Here's the 'finished' seat:



If I had more time I would have refined it more, smoothed it out and not just laid thick paint to cover up as much of the imperfections as I could. That's what happens when you budget time poorly I suppose! Happy with the shape and the fit though!

I created some designs with decals and chose the one I liked the most, a big Honda wing across the tank to balance the black/gold ratio and a little 750 on the covers to give them some detail.





Last two items, velcro the seat to the seat pan, connect the tail lights up. I'll do that this afternoon before I drop the bike off at the show for the weekend.

Thanks again to everyone at this forum, I learned so much since I first bought this bike 5 years ago and it has sparked a huge interest of mine into automotive and motorcycle projects!

[rippen2wheels]

Your bike looks great I like the changes you made, nice machine work too

[SOHC4 Cafe Racer Fan]

Does someone want to second this bike as a nominee for BOTM? Do it in the following thread:  http://forums.sohc4.net/index.php/topic,176614.0.html

[SOHC4 Cafe Racer Fan]

Does someone want to second this bike as a nominee for BOTM? Do it in the following thread:  http://forums.sohc4.net/index.php/topic,176614.0.html

Bump!!

[SOHC4 Cafe Racer Fan]

mkoski,

Congratulations! You're bike has been nominated and seconded as a candidate for a future Bike of the Month.  Please post that you "accept" the nomination in the following thread so it can be eligible for voting:  http://forums.sohc4.net/index.php/topic,176614.0.html

Don