Topic: Cb650 Cafe racer

[SOHC4 Cafe Racer Fan]

Damn! DaveBarbie and I might be interested in your VFR800 upgrade to the charging system.  Let us know the specs and what's involved OR if you're willing to turn out a couple more for us!  I assume this is a 32 AMP upgrade, right?

I'll post a more detailed description when I'm done. If it works

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

With the 32 amp system, the bike will charge at idle and you can run accessories including a charger or heated gear.

[grcamna2]

Really cool conversion on the charging system. from what i can remember the vfr reg/rec is of the more modern mosfet typ, perhaps wouldnt be bad to incorperate that aswell? Looking forward to se the results.

Yes that might be the case. It's bigger anyway.

But I'll upgrade to an even more modern regulator later. It's in the plan to switch to a 4 cell lithium battery. A bit small maby, but it's cooler to do a run start of the bike if needed I have a small 7Ah lead battery now and that works great.

I installed a Shindengen Mosfet style 5-wire Reg/Rect. into my 82' Suzuki GS450TZ with the number #SH775.
I was told by reliable people on another forum this will make my stator last much longer,not like my original reg./rect. which is a 'shunt type' that keeps the alternator running full output even when not necessary.

[DaveBarbier]

Damn! DaveBarbie and I might be interested in your VFR800 upgrade to the charging system.  Let us know the specs and what's involved OR if you're willing to turn out a couple more for us!  I assume this is a 32 AMP upgrade, right?

I'll post a more detailed description when I'm done. If it works

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

With the 32 amp system, the bike will charge at idle and you can run accessories including a charger or heated gear.

Ah ok, my bike charges at idle but I’m running all LED lights and no accessories.

[dkihlgren]

Damn! DaveBarbie and I might be interested in your VFR800 upgrade to the charging system.  Let us know the specs and what's involved OR if you're willing to turn out a couple more for us!  I assume this is a 32 AMP upgrade, right?

I'll post a more detailed description when I'm done. If it works

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

With the 32 amp system, the bike will charge at idle and you can run accessories including a charger or heated gear.

Ah ok, my bike charges at idle but I’m running all LED lights and no accessories.

I will be running a powerful headlight and heated grips for our dark and cold Swedish season

[onepieceatatime]

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

In my experience, a lot of the problem with the CB650 charging system is that the rotor is prone to failure, which usually takes out the rectifier/regulator when it fails.

[dkihlgren]

Got some stuff done today! Starting to look like a bike and not a pile of parts

[grcamna2]

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

In my experience, a lot of the problem with the CB650 charging system is that the rotor is prone to failure, which usually takes out the rectifier/regulator when it fails.

Rotor or Field coil ?

[grcamna2]

Got some stuff done today! Starting to look like a bike and not a pile of parts

That is a nice cafe custom.I like the work you completed on the rear swing arm 

[onepieceatatime]

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

In my experience, a lot of the problem with the CB650 charging system is that the rotor is prone to failure, which usually takes out the rectifier/regulator when it fails.

Rotor or Field coil ?

ROTOR  31110-425-005

The DOHC bikes of the generation had the same charging system with the same issues.

[grcamna2]

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

In my experience, a lot of the problem with the CB650 charging system is that the rotor is prone to failure, which usually takes out the rectifier/regulator when it fails.

Rotor or Field coil ?

ROTOR  31110-425-005

The DOHC bikes of the generation had the same charging system with the same issues.

Not enough magnetic power ?

[onepieceatatime]

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

In my experience, a lot of the problem with the CB650 charging system is that the rotor is prone to failure, which usually takes out the rectifier/regulator when it fails.

Rotor or Field coil ?

ROTOR  31110-425-005

The DOHC bikes of the generation had the same charging system with the same issues.

Not enough magnetic power ?

They are an electromagnet; insulation on the windings break down and they fail, or the windings break. When they are good they are in the 4-8 ohm range, measured between the sliprings.

[grcamna2]

Ok,Thanks for that information. 

[DaveBarbier]

Damn! DaveBarbie and I might be interested in your VFR800 upgrade to the charging system.  Let us know the specs and what's involved OR if you're willing to turn out a couple more for us!  I assume this is a 32 AMP upgrade, right?

I'll post a more detailed description when I'm done. If it works

Liking the build so far! What’s the benefit of upgrading the charging system? My 650 charges fine and makes a surplus at idle. I’ve only heard people say these have charging problems but haven’t seen anyone post about an issue. Before the tear down did yours have problems?

With the 32 amp system, the bike will charge at idle and you can run accessories including a charger or heated gear.

Ah ok, my bike charges at idle but I’m running all LED lights and no accessories.

I will be running a powerful headlight and heated grips for our dark and cold Swedish season

Totally understandable, haha.

[dkihlgren]

Making an adapter for external oil lines to camshaft. Have to mill 17mm hex and cut off. I'll use M8 banjo fitting and steel braided lines.

[DaveBarbier]

Making an adapter for external oil lines to camshaft. Have to mill 17mm hex and cut off. I'll use M8 banjo fitting and steel braided lines.

I was really considering the external oiling modification. I said to myself once this motor starts leaking I’m going to do it. Haven’t gotten to it yet because my motor is bone dry, haha. Very cool mod. Where will you feed from? I’m assuming the oil gallery plug on right below ignition cover but I’ve heard some trying to do it from the left inside the generator cover so it’s protected.

[dkihlgren]

Making an adapter for external oil lines to camshaft. Have to mill 17mm hex and cut off. I'll use M8 banjo fitting and steel braided lines.

I was really considering the external oiling modification. I said to myself once this motor starts leaking I’m going to do it. Haven’t gotten to it yet because my motor is bone dry, haha. Very cool mod. Where will you feed from? I’m assuming the oil gallery plug on right below ignition cover but I’ve heard some trying to do it from the left inside the generator cover so it’s protected.

Yes I'm using right hand side. Figure a small banjo is a bit protected.

[DaveBarbier]

Making an adapter for external oil lines to camshaft. Have to mill 17mm hex and cut off. I'll use M8 banjo fitting and steel braided lines.

I was really considering the external oiling modification. I said to myself once this motor starts leaking I’m going to do it. Haven’t gotten to it yet because my motor is bone dry, haha. Very cool mod. Where will you feed from? I’m assuming the oil gallery plug on right below ignition cover but I’ve heard some trying to do it from the left inside the generator cover so it’s protected.

Yes I'm using right hand side. Figure a small banjo is a bit protected.

Yeah I’d say so. That’s where I’d go from if I was doing the mod. Just make sure to put a restriction in the lines the same size as the the factory designed system. I’m sure you did the research but of course you want proper pressure. Any change will affect the crank pressure.

[dkihlgren]

Making an adapter for external oil lines to camshaft. Have to mill 17mm hex and cut off. I'll use M8 banjo fitting and steel braided lines.

I was really considering the external oiling modification. I said to myself once this motor starts leaking I’m going to do it. Haven’t gotten to it yet because my motor is bone dry, haha. Very cool mod. Where will you feed from? I’m assuming the oil gallery plug on right below ignition cover but I’ve heard some trying to do it from the left inside the generator cover so it’s protected.

Yes I'm using right hand side. Figure a small banjo is a bit protected.

Yeah I’d say so. That’s where I’d go from if I was doing the mod. Just make sure to put a restriction in the lines the same size as the the factory designed system. I’m sure you did the research but of course you want proper pressure. Any change will affect the crank pressure.

Yes my plan is to insert a modified main jet in the banjo bolt. Will use my jet reamer kit so it's the same size as old restrictions.

[dkihlgren]

M24x1.5 to M8x1.0 adapter finished. Could not find a caliper when I was milling the hex. So I eye balled it and figured I can always use a wrench... By luck I got a super tight fit to a 19mm socket. What are the odds? Next version will be shorter for a cleaner look

[DaveBarbier]

Very nice! I was going to ask whether or not you would modify the existing plug because it’s quite thin. This is much better, but without some sort of flange to press on the case it won’t be able to be torqued down, right? Might it spin when you try and tighten down the banjo bolt?

[dkihlgren]

Very nice! I was going to ask whether or not you would modify the existing plug because it’s quite thin. This is much better, but without some sort of flange to press on the case it won’t be able to be torqued down, right? Might it spin when you try and tighten down the banjo bolt?

I just copied the original plug. There is a difference between 550 and my 650.

[DaveBarbier]

Very nice! I was going to ask whether or not you would modify the existing plug because it’s quite thin. This is much better, but without some sort of flange to press on the case it won’t be able to be torqued down, right? Might it spin when you try and tighten down the banjo bolt?

I just copied the original plug. There is a difference between 550 and my 650.

Oh sorry, you’re right, forgot our 650’s have that kind of plug. Carry on

[dkihlgren]

Damn! Had my measurements wrong. Have to modify my swing bracing. My idea is to make a cut out in the tube so the chain has some room. Then I'll weld some sheet metal to close it up.


Made one restricted banjo bolt for head oil lines.

[DaveBarbier]

Damn! Had my measurements wrong. Have to modify my swing bracing. My idea is to make a cut out in the tube so the chain has some room. Then I'll weld some sheet metal to close it up.


Made one restricted banjo bolt for head oil lines.

How much room do you need? Would going to a thinner 520 chain give you the clearance? And nice main jet, haha

[SOHC4 Cafe Racer Fan]

That's not much room even if you swap to a 520 to allow for any slack.  I know it seems more drastic, but if you are going to mod the brace, why not replace with with a wider arc piece (symmetrical on both sides) to accommodate the chain.  I know that the brace is primarily to increase rigidity than structural integrity, but it seems like notching neuters it as a bracing device and makes it more cosmetic.  Up to you though.