Author Topic: Build 201 (Read 21834 times)

Daggless888 · « **Reply #75 on:** April 06, 2018, 01:12:38 am »

I want to fit a later model flush gas cap. Found a wrecked donor tank from a cbr250 and cut out the recess. It looks like it will fit into the cb650 tank really nicely. the lines on the top of the tank match up really nicely with the cap. The donor tank had a pipe from under the recess going to base of the tank where an overflow tube was fitted. I'm just going to block this off. The cap is vented so shouldn't be required. Will leave the top hole in place for any overfill. The only part I'm a bit nervous about is the need to reline the tank. I've been reading up on por15 and there seems to be a lot of failures. Granted there is a common thread relating to preparation issues but still not sure. Is there any recommendations other than por15

calj737 · « **Reply #76 on:** April 06, 2018, 04:50:32 am »

Caswell is another good choice. I've also been experimenting with Master Series Silver. It seems to be very good, but testing is early stage.

Daggless888 · « **Reply #77 on:** April 12, 2018, 01:31:54 am »

Back into waiting mode for fork legs at anodiser and head getting O/S valves fitted. Hopefully back for the weekend. Finished rebuilding oil pump so put that in tonight. Getting cold in the shed again. Must mean another riding season coming to an end.:-(

Daggless888 · « **Reply #78 on:** April 21, 2018, 10:30:41 pm »

Head returned from being machined so was able to get everything buttoned up. Checked valve clearances as I have the 1mm oversize valves in this head. Degreed the cam. all looking good. Fitted external oil lines. Engine has turned out nice. So it's back to the frame to finish off a couple of bits then final breakdown for paint and powder. Getting closer.

Daggless888 · « **Reply #79 on:** May 09, 2018, 02:11:49 am »

a bit of a hold up for the last few weeks. I took my fork outer tubes in to be re anodised in black. They were gold but wanted black to match all the other black that I have happening. They had to do them twice as the 1st try was all sticky and a weird color. Picked them up after a second try and they looked perfect. Got them home and started to put them back together and found they had mysteriously expanded. The top caps wobbled in the threads and the seals would fall out!!!! A bit of discussion with the shop and they paid for 2 new outers. 3 weeks wait for them to arrive and we are underway again. Frame all broken down and ready for powder.

Daggless888 · « **Reply #80 on:** May 22, 2018, 01:42:50 am »

Got the phone call today that the powder coaters had finished. Rushed in to pick everything up. They did a fantastic job again. So off we go with the final stage.

Daggless888 · « **Reply #81 on:** May 22, 2018, 01:45:47 am »

All balls roller bearings installed. New swingarm bushes in.

Daggless888 · « **Reply #82 on:** May 23, 2018, 02:59:35 am »

2012 GSXR BPF conversion all fitted up. Cognito Moto top clamp. Everything bolted up nicely. Onto the swing arm. Inner shaft is tight in the bronze bearings. Nothing in the service manual about clearances. Anyone know what the clearance should be?

rosewood · « **Reply #83 on:** May 23, 2018, 03:42:22 am »

Looking good there.....

There are specs in the manual for rear swing arm pivot if you look closer...specs for the collar diameter and internal bush diameter, you need a bore gauge to measure the inside correctly though.

I posted this in someone else's thread a few weeks ago...

http://forums.sohc4.net/index.php/topic,171903.msg2001361.html#msg2001361

If its tight that's a good thing, you can use a small brake cylinder hone to resize once fitted...they may just be slightly out of round after being pressed in also...clearance ive been told to shoot for 0.01-0.025mm.

I ended up having to buy a new collar which gave me a loose fit with those bronze bushes....resorted to making my own bushes out of bronze...was still a bit of trial and error getting a good fit once pressed in.

SOHC4 Cafe Racer Fan · « **Reply #84 on:** May 23, 2018, 08:57:10 am »

The front GSXR fork looks good. You may want to consider (down the road, if not now) a new set of triple trees. The stock offset of the GSXR fork is much smaller than that of the CB550. Using the smaller offset changes the geometry of the bike and can make the bike both twitchy and feel wants to fall into corners. Given the amount you've spent on wheels, tires and other upgrades, this may be worth it.

Daggless888 · « **Reply #85 on:** May 24, 2018, 02:05:29 am »

Quote from: rosewood on May 23, 2018, 03:42:22 am

Looking good there.....

There are specs in the manual for rear swing arm pivot if you look closer...specs for the collar diameter and internal bush diameter, you need a bore gauge to measure the inside correctly though.

I posted this in someone else's thread a few weeks ago...

http://forums.sohc4.net/index.php/topic,171903.msg2001361.html#msg2001361

If its tight that's a good thing, you can use a small brake cylinder hone to resize once fitted...they may just be slightly out of round after being pressed in also...clearance ive been told to shoot for 0.01-0.025mm.

I ended up having to buy a new collar which gave me a loose fit with those bronze bushes....resorted to making my own bushes out of bronze...was still a bit of trial and error getting a good fit once pressed in.

Cheers rosewood. Will give them a bit of a hone to get the clearance correct.

Daggless888 · « **Reply #86 on:** May 24, 2018, 02:15:08 am »

Quote from: SOHC4 Cafe Racer Fan on May 23, 2018, 08:57:10 am

The front GSXR fork looks good. You may want to consider (down the road, if not now) a new set of triple trees. The stock offset of the GSXR fork is much smaller than that of the CB550. Using the smaller offset changes the geometry of the bike and can make the bike both twitchy and feel wants to fall into corners. Given the amount you've spent on wheels, tires and other upgrades, this may be worth it.

Will keep that in mind once I get her moving. If there's any nervousness then new triples it is. Shipping and exchange rates can make the eyes water sometimes. I try to keep within a budget but then find lots of new shiny stuff that turns into must haves. :-)

SOHC4 Cafe Racer Fan · « **Reply #87 on:** May 24, 2018, 07:17:02 am »

Here's a photo of the Cognitomoto adjustable offset triple trees for your forks. It allows you to run different offsets, so if you change to 18" or 17" wheels you can adjust the offset accordingly.

image_zpsjpiysiex by

Daggless888 · « **Reply #88 on:** May 25, 2018, 12:28:04 pm »

Swingarm back in. A bit of a hone of the new bushes and pivot pushed in nicely. I was struggling with getting the arm back in with the dust caps on. Measured everything and was only a smidge in it but buggered if it would go back in. A coffee and think time and was just getting the jack out to spread the frame when I turned the whole frame upside down. The swing arm then slid back in with a couple of small persuasive taps to line it up. Almost like the underneath is slightly tapered. Perhaps I'm just lucky or it is ever so slightly worn from the underneath. Either way I will take the win without having to rig up the jack. Don't want any scratches on the finished product.

Daggless888 · « **Reply #89 on:** May 25, 2018, 12:34:03 pm »

Milestone reached last night. Motor is finally back in the frame. did the old motor on its side on the floor and lifted frame over the top. Looks so wrong with it on its side but excellent way to get it back in. Couldn't bring myself to take a photo of it laid over. Onto the controls and then the fun part. WIRING !!!!!

SOHC4 Cafe Racer Fan · « **Reply #90 on:** May 25, 2018, 08:42:44 pm »

It's starting to look like a motorcycle again! Great looking motor!

Daggless888 · « **Reply #91 on:** May 25, 2018, 09:37:05 pm »

Tarozzis fitted with Gcraft reservoir. Keeps everything compact and tidy.

Daggless888 · « **Reply #92 on:** May 25, 2018, 09:40:17 pm »

Quote from: SOHC4 Cafe Racer Fan on May 25, 2018, 08:42:44 pm

It's starting to look like a motorcycle again! Great looking motor!

Really happy with the look of the motor. was a bit worried with the amount of black but it's looking ok at the moment. Still haven't fully decided on tank color but will put it on soon and see what color combo matches.

Daggless888 · « **Reply #93 on:** May 27, 2018, 01:42:12 am »

Momentary switches all wired. I wish I could say they were easy and I really enjoyed doing them but geez they are fiddly. Just have to fit the plugs into end of bars and all sealed up. Blinkers on. Motogadget, solenoid and regulator/ rectifier in place. Steering damper on. A busy but rewarding day.

SOHC4 Cafe Racer Fan · « **Reply #94 on:** May 27, 2018, 09:46:56 am »

Quote from: Daggless888 on May 25, 2018, 09:40:17 pm

Quote from: SOHC4 Cafe Racer Fan on May 25, 2018, 08:42:44 pm
It's starting to look like a motorcycle again! Great looking motor!

Really happy with the look of the motor. was a bit worried with the amount of black but it's looking ok at the moment. Still haven't fully decided on tank color but will put it on soon and see what color combo matches.

When you murder out a bike, the use of color becomes more important. Here the eye is going to go to the gold wheels, so you will want some color that will balance/complement the gold.

Daggless888 · « **Reply #95 on:** May 29, 2018, 02:48:00 am »

And then the fun starts. Using the new motogadget blue on this one. The basic wiring is fairly easy. It's just the add ons like speedo that confuse the issue. Lots of reading of diagrams and backwards and forwards to the gadget book. A bit of head scratching and more reading. Then another wire goes in. Then more reading. Just takes time.

calj737 · « **Reply #96 on:** May 29, 2018, 03:09:13 am »

I find it a LOT easier to work from the push buttons on either side to the M-Unit. Think of it this way: everything on the left side of the M-Unit is a control signal "input". Everything on the right side is "switched power", or a service loom.

I separate the LH and RH input wires into 2 separate looms, routed down the backbone on their opposite side (for lock-lock) length. Then punch them down into the M-Unit.

Coming out of the M-Unit, I break down the FL and FR service looms into their own sheathing. I also run a set of power wires forward to serve the gauges, ignition, and any other needs. I run a single loom rearward to serve the LR and RR indicators, a single BRAKE/TAIL wire, and you're done.

If you are using your mobile to function as your gauge, that eliminates a few power wires, but replaces those with sensors. I've wired so many of these things up, it takes me now about 5 hours start-to-finish if all components are in place and materials in hand.

Overall, your bike is coming very nicely (again) and looks the teets

DurangoCB · « **Reply #97 on:** May 29, 2018, 05:24:51 pm »

Looks so clean and tight and the stance of that bike is going to be beautiful. I'm right behind you with my first m.unit Blue install and complete rewiring, so I'll be following along closely.

Daggless888 · « **Reply #98 on:** May 30, 2018, 12:26:23 am »

Quote from: calj737 on May 29, 2018, 03:09:13 am

I find it a LOT easier to work from the push buttons on either side to the M-Unit. Think of it this way: everything on the left side of the M-Unit is a control signal "input". Everything on the right side is "switched power", or a service loom.

I separate the LH and RH input wires into 2 separate looms, routed down the backbone on their opposite side (for lock-lock) length. Then punch them down into the M-Unit.

Coming out of the M-Unit, I break down the FL and FR service looms into their own sheathing. I also run a set of power wires forward to serve the gauges, ignition, and any other needs. I run a single loom rearward to serve the LR and RR indicators, a single BRAKE/TAIL wire, and you're done.

If you are using your mobile to function as your gauge, that eliminates a few power wires, but replaces those with sensors. I've wired so many of these things up, it takes me now about 5 hours start-to-finish if all components are in place and materials in hand.

Overall, your bike is coming very nicely (again) and looks the teets

5 hours !!! Geez Cal. It took me that long to read the instructions. Sometimes overthinking it leads to doubts. When you take it back to its basics there's only 5 wires going from front to back and a couple of extras back the other way. My eyes keep getting diverted to the 25 wires that the speedo is asking for. I might throw a rag over it and get the basics done then tackle it seperately.

calj737 · « **Reply #99 on:** May 30, 2018, 04:26:39 am »

Quote from: Daggless888 on May 30, 2018, 12:26:23 am

My eyes keep getting diverted to the 25 wires that the speedo is asking for.

Damn Acewell gauges!

Serves you right for cheating out and not using a MotoG instrument

I see 64 hours of wiring heading your way now

(I'm busting your chops of course, or "having a piss" as is said in the SoHem).

I wired the Fox350 for Devin a couple of years ago. The first time, he wasn't quite "done" with the fabrication, but was behind on schedule due to some custom stuff. So I wired it. Then he changed and added a bunch of stuff, so I had to redo a LOT.

Then he made some more changes, and what had started as a neat and tidy install, became a jumble of junk. So I unwired everything, replanned everything, then wired it out. Again. The final time I wired it, it took me a little over 6 hours (mostly because I had wired it already twice in effect). But that darn bike had every possible aftermarket, upgraded electrical anything ever made for a vintage bike. Major PITA to do, amplified by the absolutely ZERO space to locate or hide anything. I actually stuffed the Reg/Rec in the hollow upright tube after drilling some venting holes for fresh air circulation. The seat hump on that was as large a mosquito bite on a newborn too.

So if you cut some lengths of your service looms, temporarily tape them in a bundle, lay them out physically where you want them to run. It allows you to get organized and reduce the intimidation by seeing how simple it all really is.

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Author Topic: Build 201 (Read 21834 times)