Topic: My 79 CB650 project - it's a slow process

[RM81]

Starting a new thread to follow the progress on my 79 CB650.  My plans are to start this after hunting season and finish it by spring.  I just got this bike a couple of weeks ago and it runs, but is a little rough.  It looks like it's been sitting for quite a while hence all the bird poop.  When I opened the gas cap, the stench knocked me back a little so I'm sure I'll have fun cleaning the varnish out of the tank/carbs/engine.  This is going to be a slow project so don't expect quick updates.  Here it is as I got it.  Just over 15k miles.  The seat is in great shape, tank has one small dent, cracked headlight, dented tach housing, broken light panel, stained engine case from old gas overflow, broken clutch lever, broken turn signals, blinkers inop, and probably lots more.  Those are the things that stick out.

[RM81]

To the best of my knowledge, most everything from '80 thru '82 is interchangeable until you get to the carbs and engine.  The isolators that work with the '81-'82 carbs are too big to work with the '80 and '79 carbs.  I've heard tell the '79 frame is 'completely different' but I don't know exactly 'how' except that the seat and tank look different.  The '80s got regular sealed beam headlights, but '81-'82 had halogen.  I think also the '81-'82 has a different, two-screw master cylinder, possibly larger for the '81 and '82 custom's dual disks.    Oh, check your igniters under your seat, next to the battery.  Almost every 650 I've seen, the black plastic covering on the back is melted to death.  I replaced mine, but the black plastic dripped down beneath my battery cover etc. 

So what parts have you guys/gals found to be interchangable between the different years?

Well...
Differences:(CV(most '80 and all '81 and '82's) bikes Vs. Mechanical carb bikes('79 and some '80 cb650's)

The '79 kickstand has the spring on the inside of the frame, '80-'82 on the outside

Sidecovers, obvious difference visually, mount points do not match up.

Seats do not swap

Tanks do not swap

Tripple trees are different spacing, but forks are same diameter.

rear rim swap is straightforward.

Swingarm swap is not, soemewhat involved with this one.

CDI units are same all years.(can use DOHC750/900/1100 units as well)

engines swap all years

heads swap all years

turn signals swap '80-'82, '79's are unique among the cb650's

exhausts are not a straightforward swap.
a '79 4-2 exhaust fits the '80-'82 frame ok. the 4-4 fits the '79, but interferes with the

kickstand spring post on the frame.

headlight mounts are different.

neck bearings are the same

Tripple trees swap easily.

coils are swappable

air cleaners are not swappable.

Inner plastic fender off a '80-'82 frame will fit a '79 frame if using pods, and you want to eliminate the airbox(not a perfect fit, but it works)

And thats just , besides the obvious frame differences.

And that list is just off the top of me head for 650 to 650 swaps i've tried....
Not to mention the non cb650 parts onto a cb650 i have failed at or succeeded at.

l8r

Don't forget, thats only for the US version.
As for non US "Z" models, I have no idea. Have YET to get one.

info for later on.

[RM81]

    Oh, check your igniters under your seat, next to the battery.  Almost every 650 I've seen, the black plastic covering on the back is melted to death.  I replaced mine, but the black plastic dripped down beneath my battery cover etc. 

The killer of those CDI units tends to be a failing charging system, or leaving the ignition on with the motor not running.

And yes the frames are REALLY different.

The '80-'82 are a lower seating setup, the '79 sits higher...
Swingarms on the 2 different feames are different as well.
Do a search I have swapped a '81(?'80?) swingarm on my '79 frame.
The pivot tube is smaller on the '79 swingarm, so custom bushings are needed.

If you ever get a chance to park your next to a '79 and compare(or you '79 owners park next to a '80-'82) and note the differences.

And thats only within the US.
Then there is the "Z" model the rest of the world got, thats another beast unto itself...


l8r

So I'm guessing this is what you two are talking about?

[RM81]

The PO told me he replaced the battery, but it would never hold a charge.  I'm guessing it never charged at all.

[hoodellyhoo]

I'm no 650 expert, but I'm going to go ahead and assume that the duct tape on the headlight bucket isn't stock

Good luck with the project. Love the look of the 79's.

[DollarBill]

What never ceases to amaze me about this forum is that nothing slips by...   

I'm no 650 expert, but I'm going to go ahead and assume that the duct tape on the headlight bucket isn't stock

Good luck with the project. Love the look of the 79's.

That cracks me up

Good luck with the build.

[RM81]

I'm no 650 expert, but I'm going to go ahead and assume that the duct tape on the headlight bucket isn't stock

Good luck with the project. Love the look of the 79's.

Man you just saved me loads of time.  I wasn't sure where I'd find original duct tape from the 70's.

[Hush]

Duck tape and bird poo, some menagerie you got there.
Your old 79 looks just like my 79, so the Z model must be a world wide one.
I'm just about to add an 84 Custom to my stable (still has SOHC) and the motor is the only thing I could possibly swap from one to the other.
6th gear would have been a nice add on to the 650's.
Your pipes look good for stock ones, and take it from me they are damn near impossible to find world wide so look after them.

[RM81]

Your pipes look good for stock ones, and take it from me they are damn near impossible to find world wide so look after them.

There not too bad, but eventually I'll get something else.  I missed a great deal on ebay last week.  MAC 4-1 black exhaust went for $81.  I think my high bid was $75, but I could've gone a little higher.  Gotta love the ebay trolls that bid with 30 seconds left.  I can't complain though b/c I do it all the time too.

[Soos]

So I'm guessing this is what you two are talking about?

Yup.

I'm glad i've been able to stash a few extra electrical bits here and there...
Ok, i have 2 spare (or more) of everything.... But i've got 2 650's, one running, one a monster in the works. And I REALLY hate being stuck without a cheap electrical bit when one goes out.


Looks a sight better than the 1st cb650 I bought.

Have fun!


l8r

[RM81]

So I'm guessing this is what you two are talking about?

Yup.

I'm glad i've been able to stash a few extra electrical bits here and there...
Ok, i have 2 spare (or more) of everything.... But i've got 2 650's, one running, one a monster in the works. And I REALLY hate being stuck without a cheap electrical bit when one goes out.


Looks a sight better than the 1st cb650 I bought.

Have fun!


l8r

Is there a better aftermarket part to fix this or am I doomed to replace the OEM one every few years?

[RM81]

I know it's early, but I'm just thinking ahead.

How about John Deer Green?  Not that I'm a John Deer fan, I just want to find a bright green color that pops.  Thoughts?  I'd do the frame, handlebars, levers, exhaust, and whatever else in black.

http://www.rustoleum.com/CBGProduct.asp?pid=111&sid=7435830


Should be pretty durable if it's made for farm equipment.

[Hush]

Cool colour, my first bike (an AC50 Suzuki) was that green with white stripes........always love your first bike eh.
I've got a full set of black 4 into 1's hanging in my shed but I'm not just around the corner!

[Tim in Ohio]

I'll be watching your build Matt.  Git 'er done. 

[RM81]

Cool colour, my first bike (an AC50 Suzuki) was that green with white stripes........always love your first bike eh.
I've got a full set of black 4 into 1's hanging in my shed but I'm not just around the corner!

I'll be looking for some later on when I'm closer to completion.  If you want to sell, send me a pic, price, and what you think it'll cost to ship.  I'm still mad I missed out on that last set for 80 bucks, brand new too.

I'll be watching your build Matt.  Git 'er done. 

It won't be as fast as yours, but hopefully I'll be riding it next spring.  Once I get a compession tester, I'll check that.  Hopefully, I won't have to dig too deep in the engine.  I know I have some electrical issues to work out though.  I've been looking for good replacements other than original, but no luck as of yet.  I don't understand how all that works, but I've been doing a lot of reading the last couple of days.

[RM81]

I found a couple of useful links to manuals if anyone with a 650 is interested.  After searching the site here, I couldn't find much for the 79 model but came across this in a google search.

79 cb650 shop manual:  http://www.jasonkent.ca/cb650manual.htm


I also found a Clymer manual for the cb650 SOHC fours which I couldn't find here:

Link to the Bozeman Public Library:  http://search.ebscohost.com/
username: library
password: library
"Courtesy of Jockey Journal http://www.jockeyjournal.com/forum/showthread.php?t=36194"

EDIT* The Library website isn't working anymore.  I have a soft copy of the 650 manual if anyone needs to borrow it.


Then go to small engine repair.  There's a ton of other manuals there too.  Copyright notice says that it's free for individuals to download and use but you can't reproduce and distribute.  It took me a couple of hours to download and sort all pages, but it's free so no complaints here.

[RM81]

Ok, so I'm almost finished gathering parts.  Picked up this Vetter fairing today for a decent price.  Doesn't have the mounting bracket so I'm not sure what I'm going to do about it.  It also came with a trunk and sissy bar/back rest. 






I also got both side covers (one has a small chip which I think I can repair), speedo and tach, pilot cluster, a set of CDI's, and engine covers.  I still need to pick up a carb kit before I tear into it.  Also gotta get a battery and new tires.  I should have some free time here and there this summer to put some time in on it.  The title of the thread is ringing true.

Good news is that I'm done with my CM450 so I've got one to ride while I work on this one.

[Hush]

8 months between posts, it sure is a slow process.
Sorry pipes went to a deserving project up Auckland way, you sure you wanna put that windjammer fairing on the bike, I have enough trouble just getting to decent road speed and I only got a little screen.

[RM81]

I'm not 100% sure about the fairing yet.  I have about 30 miles of highway each way to work so I thought it might help.  I did get to ride my 450 to work today after a long maintenance period.  That was fun.  No worries about the pipes Hush.  I'm probably going to keep the ones I have anyway.

[RM81]

So I sold my only running bike to help motivate me to work on this one.  I knew the CDI's were melted so I figured why not poke around and see what I can find.  The battery charged OK and has kept a charge for a week now.  Haven't properly tested it yet though.  First place I looked was the fuse panel and found this.



Looking for some insight as to what other damage this can cause.  I'm guessing I'll have to sort out the entire wire harness looking for fried wires.  What other components can fry b/c of this?

Also, I'll be looking for a fuse panel replacement if anyone has one they'll sell me.  I thought about switching over to the blade style fuses, but I have to do some more reading on here (this place is great   to see what that involves.  Another thing I noticed was the back tire was a 16 inch.  All the manuals and parts fiches I've looked at say the 79 has a 17 inch.

[Hush]

Just how many Ohms is a rusted bolt or for that matter a tinnie (any grass in it?)
I found all mine to be 50amp fuses, not sure when the PO was gonna run it off the national grid as an electric bike?
If you can't see melted wires you should be OK, does all the indicators/lights/horn etc work?

[razor02097]

Hush I think thats a piece of spark plug wire from a car.

Creative thinking on the replacement fuses but how many amps would that bolt blow?  Kidding 

You don't have electrical issues do you?  Hope that the wiring isn't burnt up on those circuits.  Check the main fuse on the solinoid too... maybe you'll find a penny or something 

[RM81]

I had to look up what a tinnie is.   Guess I'm out of the loop.

[razor02097]

What part of Ohio are you from Rusty?

[RM81]

near London