Topic: removing stuck pistons, rotating engine to get cam loose,brake fluid

[crusierlover]

That is great information.I have to remove the rear wheel,swingarm also to get the primary chain out.The bike has sat since 1984, I thought it was 2004.I am about 90% sure i will be using one of my other 2 engines.But once this one is out i will still try to unlock it.I am not going to use a masterlink chain.these bikes are lowtorque and high rpm.I dont want a chain flying apart.chains seem to range from about $70 to over 200.I will get a used chain for about $75.Maybe o ring.I doubt I will pull the shock and fender but the battery box is barely in the bike so I may do that.Your advice is always so good.I appreciate it.

there is a product made by KBS for frame painting.It brushes on,looks like powder coat when finished.

[crusierlover]

http://www.jegs.com/p/KBS-Coatings/KBS-Coatings-Frame-Coater-Kits/1044197/10002/-1


enough to do 5 bikes probably

[crusierlover]

I am thinking about going with my 80 model now, using the 79 for parts.why? Because:
1.I have the title to the 80.
2.I have 20 80 engines, that turn over easily complete with carbs
3.The 80 already has a good front tire,and functioning brakes.
4.The reg/rectifier,solenoid,mainfuse are off the 80,but in a box.It looks like they all mount on the left,on the 79 its on the right.I have the solenoid and r/r in a box.
5.It has functioning brakes
6.It last ran and was titled in 2014.
7.I think I could part out the 79 to pay for fixing the 80.
.I have another 80 engine that also turns over, it has been in a garage, the carbs off, and all the head openings on the carb mounting points have been taped and sealed over to prevent water getting in the motor.

cons:
1.The handlebar controls are not on the 80(oops, yes they are).The ones on the 79 should transfer over.The throttle cable is there on the 80,just not connected to a throttle sleeve/handgrip.
2.Dont know where the disconnected components go.I have a manual,perhaps it shows there.It shows the 79 r/r placement,not the 80 model(oops,yes it does).The turn signals are off the 80 model.I was going to leave them
off.The headlight is missing, but all the connectors hanging out of the bucket are intact.My 79 sat in a garage for 23 years.
3.I do not want to open a can of worms on the electrical stuff
4.I feel defeated.But I think the 80 logically makes more sense.


I just studied my manual.The r/r mounts the same, the instrument panel,blinker connections,headlight ,handlebar controls, all the same.The battery,main fuse,solenoid are on the right on the 79,on the left on the 80.I am not sure how to lengthen the wires to reach from the right side mounting of the solenoid and main fuse on the 79 to the left side location on the 80,but its only about 8 inches.Since the starter is on the left already the stock wiring might reach from the right to the left side.I wish I was doing mechanical and not electrical right now.

[crusierlover]

pics of 80 starting point.I tried posting multiple pics,clicked on more atachments.perhaps the files are too big.

[rb550four]

Okay, I have to ask, how does one get 20 1980  650 engines that turn over with carbs? Mistype? Hope not, very impressed , now here's a guy determined to have enough parts to finish a project before he even starts.Good show. Hey ,even if it is a typo and you have 2 engines to play with...that is a really decent start too.
 I'm a fan of the 80 650 for suspension and horsepower reasons ,a fitting upgrade to the 550, but love the classic looks of the 79 even though it handles more like a  750 . Torn really. You shouldn't have any trouble parting the 79 out, but you may kick yourself about it later, after the bug really sets in and you realize there's no stopping it.
 Do you have an 81 custom with dual front disc brakes? Just asking, don't need another one.
  I'm watching your threads closely, lots of parts, lots of questions, lots of interest, and no fear....yeah, you've  been bitten. I think we're seeing another collector blooming. It's an interesting phenomenon that happens allot around here.

[SOHC4 Cafe Racer Fan]

Okay, I have to ask, how does one get 20 1980  650 engines that turn over with carbs? Mistype? Hope not, very impressed , now here's a guy determined to have enough parts to finish a project before he even starts.Good show. Hey ,even if it is a typo and you have 2 engines to play with...that is a really decent start too.
 I'm a fan of the 80 650 for suspension and horsepower reasons ,a fitting upgrade to the 550, but love the classic looks of the 79 even though it handles more like a  750 . Torn really. You shouldn't have any trouble parting the 79 out, but you may kick yourself about it later, after the bug really sets in and you realize there's no stopping it.
 Do you have an 81 custom with dual front disc brakes? Just asking, don't need another one.
  I'm watching your threads closely, lots of parts, lots of questions, lots of interest, and no fear....yeah, you've  been bitten. I think we're seeing another collector blooming. It's an interesting phenomenon that happens allot around here.

RB,

You bring up some valid points. Maybe you should build a Frankenstein-650 with all the good parts.

[crusierlover]

Yep.I bought the complete 79,no parts missing for $175.I never intended for it to be anything but a donor.Then I found out the z is from the uk, so I decided to fix it.Right now its going to the back burner and I am going to get the 80 going.I bought the 80 with engine carbs,tank,pipes,tires,and the other one a 79 with rolling chassis,motor,carbs,pipes both for $500.The 80 has working brakes and a title.And apparently 750 carbs.So I have lots of parts.Oddly enough I dont have sidecovers for the 80 model.I should be able to part out the 79 for more than I paid for it.But for now I am going to transplant from it to get the 80 going.Then at my leisure i will pull its engine out and se what the heck is wrong with it.It sat for 23 years.The guy said "about 8".But still I have plenty pf parts to get going.

[crusierlover]

As far as getting the bug goes, yep I would agree.Right now I want the 80 and 79 to be complete.Then I want a 750 4 pipe model.And then a 750 supersport.Then 1 either 500 or 550 and I will be done.That's not as bad as some guys.

[crusierlover]

Bikes I would like to build:
1.This 80 650, one with savior frame,springer front end,stock length .either red or yellow,solo seat,not tractor seat,bobbed rear fender,frenched tailight,electronic illuminated dash panel,motor bored to 674,stainless steel sidecovers with checkered flag on tank and 675 logo on sidecovers. racetech springs,gold emulator valves,drag bars.never ever come anywhere near clubman bars,cafe racer hoops,paper thin seat.Those are the stupidest trend in motorcycling.
2.resurrect the 79 z.complete stock.Just improved brakes,springs,handling.Never come near a sissybar or luggage rack.Once again though, the pullback handlebars have to go.

[754]

Sidecovers on an Amen frame.?  ?
And gold emulators for a springer?..?

[crusierlover]

Sidecovers on an Amen frame.?  ?
And gold emulators for a springer?..?

ha ha.good points.What I meant is if I have a stock fork then emulators.If springer or even better a girder front end then no.In regard to sidecovers, I just wanted the sprung hardtail  swingarm option of the saviour frame.It looks akin to the 41 Indian with the box around the shock.I never want a true hardtail.My daily rider is a heritage softail.Hardtails are brutal,just for show.

[crusierlover]

daily ride

[rb550four]

  Very nice.

[crusierlover]

thanks.

[crusierlover]

I found out  only 5,000  79's were made.So this week  i will get the motor out.Probably replace.But I have another one.It will suck if none of the motors are any good.But 2 of them turn over freely, so that gives me hope.I think the one in the 79 is totally toast.I was about to strip it to fix the 80.But now I am not.The 80 is pretty complete, it can wait.It is the coolest day of the week today.101.Makes working in the garage or the driveway most unpleasant.I am cleaning out my shed, to work in there.I can be in there late at night with the door open and a floor fan.It gets down to mid 90's after midnight.

[rb550four]

Ah , a man of many motors.

[754]

This may fire you up,  rode a ways with him yesterday, he puts his feet up on the cases while riding..

[crusierlover]

This may fire you up,  rode a ways with him yesterday, he puts his feet up the next the cases while riding..

so his foot on the ground  hiding the footpegs?

[754]

Yes

[crusierlover]

Just got the carbs off.Almost impossible. will definitely be moving the battey box and rear fender going back on.

[crusierlover]

well,heat index supposed to be near 115 today.I suppose about 8 pm when its down to 90 I will go out in the garage and a big fan and get the motor out of the 79.I sure am curious to tear it down and see what got the engine so stuck.I suspect rings rusted to the cylinder walls after sitting 23 years.I will post pictures.I priced sleeves, $99 each.I wont go that route.I have found entire blocks on ebay for $50.

[crusierlover]

I spent a little time on getting the emotor out of the 79 yesterday.All I want is to get it out of the frame,then start dissassembling it,find out how bad it is.My manual has some parts to engine removal I am questioning.The carbs and exhausts are off, of course the brake pedal and footpeg.I see several bolts to remove holding the engine in.I can see why any electrical connections like neutral switch or oil pressure switch and so on need to be unhooked.But why would I need to remove the rotor and alternator? Also, all the bolts and nuts are pretty much immoveable.The engine mounting bolts i am hoping do not snap off.The clutch cable where it connects to the clutch cover I thought would just lift out of the slot,but i had to remove the cover and disconnect internally the cable.Even with the cable unhooked the clutch lever on the handlebar will not move.Totally rusted from time sitting.The same with the brake lever.But that mastercylinder is trash and I have a replacement,but the big screw holding it on is immoveable.I only wanted the lever as a spare.The handlebar switches on the left clutch side I had taken apart to get them slid off the handlebars.One piece inside fell out,some sort of grey metal piece that might have been a contact point.That part seems broken in 2 pieces.More ebay i guess.But, other than removing the engine mounting bolts and all the cables being unhooked,electrical connections unplugged, isn't that enough to pull the engine? I could hardly believe inside the handlebar switch was spider nests, and down inside the holes where i removed the headbolt covers also.

So,back to the task.I am learning a lot, also realize I will not start from below zero next time.But it is a good way to see what makes these bikes tick.

[crusierlover]

I just saw a great youtube video on removing a rotor.Once you get the big bolt out,screw a rear axle into the threaded portion.Tighten it.Then hit the end of the axle a few times with a small sledgehammer.It pops the rotor off.

[crusierlover]

I finally got the motor out.That is really hard.I don't see how you guys swap engines in and out like its nothing.I know putting it back is going to be harder.I found out when it seemed like the motor was stuck and never going to come out of the frame, lift it up in front and then it comes out pretty good.now  way its going to come out unless you lift the front of the motor up.Taking my doner motor out ought to be a lot easier. I am going to out this on my motor stand, take it apart more,see why its not turning over.99% sure its rings rusted to cylinders.here are a picture of the crusted motor and the crusted engine bay.Yep, this is going to be a long project.

[SOHC4 Cafe Racer Fan]

When you are ready to install the motor and the frame is cleaned up, you can lay the motor on its side and place the BARE frame over the motor, slide in your mounting bolts and then tilt the frame back upright. 

Install the other components AFTER you do this.