Topic: 1980 cb650c cafe project

[Myaspops64]

Not sure if u can see well enough in this pic but it’s as if the distance between the groove that the bottom of the tensioner sits in and the adjusting bolt is too big...when the tensioner is in its perch at the bottom properly, the adjusting bolt is above the hole it is supposed to come out of.

[Myaspops64]

I’m not sure what you’re seeing but the cylinder walls seem to be smooth to me

[Myaspops64]

Another thing is that when I try to pull my starter clutch from through the oil pan, the holes in the outer case of the clutch(these holes are supposed to line up with the torx bolts) are not lined up properly. The edge of the hole in the outer cover is covering like 1/3 of the torx bolt head, so I can’t even get my torx bit on the bolt to remove the starter clutch

[Myaspops64]

Pics of starter clutch

[rb550four]

Is that last picture today's picture of you putting it back together?
  If so you are having troubles because the cam tensioner still isn't in it's perch.
 

[rb550four]

Those cylinder walls look good to you? You should look at your picture and zoom in on the vertical gouge on #1 , deep double rust scars on #4 ,and at least one rust scar that I can see well from here in #3 .
 feel smooth??? The PO probably honed the living #$%* out of them, at this point it doesn't matter how smooth they feel , are they egg shaped, are they within tolerances and serviceable with  the rings and pistons that you are using?They are probably the original rings. Do you already have piston slap? What's the skirts look like. Did you measure anything  here to see if it was within tolerance and serviceable before deciding to put it back together? and together wrong.
  Read the manual, understand the manual , you will find most everything you will ever need to know and how to do it in the manual. don't read the manual and you are doomed to fail.
  Removing the same #$%*ty parts and reassembling it with those same #$%*ty parts is insanity, you will never have a decent running machine that way .
 It's just a waste of time, your time and mine . See ya.

[Myaspops64]

Well I haven’t put anything back together at all lady...plus you really haven’t done anything to help me anyway. You do nothing but discourage me from trying to do anything with the bike...it’s not your project, it’s mine. I’ll change what I think needs to be changed. You shouldn’t be crying about anything I’m doing at all...I joined this site to get a little help with some of the things I needed help with...you haven’t actually helped me with anything. “Did you do this? Did you do that?...OMG! Stop wasting my time.”...your time??? Maybe you misunderstood me when I said I needed some help/hints/tips...if so, my apologies...wish u the best

[Myaspops64]

And I’ve been using the manual for the entire process, however the manual says nothing about what my main problem is...it tells me how to remove the starter clutch...the problem is that the outer cover to the clutch is slightly covering the bolt heads I’m supposed to remove...I need to get the starter clutch outer cover rotated just enough to clear the torx bolt heads, so I can get the bit in them

[SOHC4 Cafe Racer Fan]

Myaspops64,

RB is VERY well-versed with CB500, 550 and 650 bikes.  He's owned and build more than many collectors put together.  He really is trying to help you out - he's learned the hard way and the easy way - and I think he's genuinely trying to help you avoid some pitfalls. Focus on his suggestions/heads up warnings.

The photos are not the clearest on my phone, but I can see what appears to be some good scoring marks on the #1 cylinder.  An overbore might be in your future.

[Myaspops64]

The fact is that my garage and my wallet are not capable of going through this entire engine the way I’m sure I should. That’s my reality. My intent is to get it as right as I’m capable of and put it back together to the best of my abilities. I can’t machine this engine and replace any parts that might be a little worn. I’ve got the gasket kit coming. I need to figure out how to get the starter clutch out and fixed, and how to get the chain tensioner to fit in properly. I’ve clearly stated the issues I need help with, and nobody has really offered any information that has been helpful with these issues...I thought it would be good to have some help but all that’s happened is I’ve been criticized and my bike has been criticized...I have to take what I’ve got, and my situation, and make the best of it