Author Topic: Rebirth of paulages' cb735 (Read 115500 times)

Doctor_D · « **Reply #425 on:** April 08, 2011, 01:28:57 PM »

I left the kickstart gear out when I did mine...

paulages · « **Reply #426 on:** April 08, 2011, 01:40:23 PM »

Quote from: Doctor_D on April 08, 2011, 01:28:57 PM

I left the kickstart gear out when I did mine...

Kickstart assembly can be installed through the bottom...

Anyway, I fixed my boo boo and the cases are back together and the clutch assembled. All I need is to figure out my base gasket situation. hmmm.

paulages · « **Reply #427 on:** April 09, 2011, 07:24:56 PM »

You know you've been through a lot when you say to yourself, "eh, that's an easy fix.. I just have to split the cases."

I got the engine together up to the head last night, and just before leaving found a crack in my top case... yes, a crack. I didn't have the heart to tear back into it last night, but believe me I thought about it a lot. Sometime about 2am, I realized what had happened: the mainshaft needle bearing had rotated when I was putting the bottom case on, and the alignment dowel had pushed through the case when I bolted it up.

Still, I was pretty certain I knew this was what had happened and sure of my solution, so this afternoon I continued with timing the cam and buttoning up the top end before I flipped the engine over and... thought to myself, "eh, that's an easy fix.. I just have to split the cases."

Sure enough, this was the problem. I pushed the split piece back into place, JB welded it from the outside, and for good measure put a dab of 1194 on the bottom of the alignment dowel and put it back together. This dowel shouldn't see any pressure, nor is there really any oil behind it, so I'm pretty sure the fix should work. The whole operation problem cost me 45 minutes.

Anyway, here it is back together. Just grabbed a 22 of IPA and am about to put it in the frame. Can't start it until tomorrow when the JB weld has cured, but it's still a huge step forward.

RAFster122s · « **Reply #428 on:** April 09, 2011, 09:01:43 PM »

She looks good sitting there on the bench built up ready to install. I'm glad you have her back to this stage of together...won't be long and you'll have it back together.

You ever consider a red and white pinstripe on the wheels to tie in with the tank and tail cowl & fairing?

David

paulages · « **Reply #429 on:** April 09, 2011, 09:41:26 PM »

Ok, time to go crack a beer (well, one at home anyway). I just need oil and a battery and it's ready to go. Cross your fingers for me!

RAF- yeah, someone else on here suggested the same thing with the pinstripe on the wheels. I tried it and it didn't really suit my fancy.

bwaller · « **Reply #430 on:** April 10, 2011, 04:21:43 AM »

Are the stars aligned?

Give er Paul.

paulages · « **Reply #431 on:** April 10, 2011, 11:23:13 AM »

Quote from: bwaller on April 10, 2011, 04:21:43 AM

Are the stars aligned?

Give er Paul.

I don't know, but the coffee grounds in the bottom of my cup were in the shape of a Honda wing, so I think I may be in business.

Greggo · « **Reply #432 on:** April 10, 2011, 02:52:13 PM »

Dead. Sexy. Machine.

paulages · « **Reply #433 on:** April 10, 2011, 05:12:53 PM »

Ladies and gentlemen, we have a runner. No apparent oil leaks yet...

Tintop · « **Reply #434 on:** April 10, 2011, 05:29:50 PM »

Congrats, and hoping the oil gods are kind to you.

tweakin · « **Reply #435 on:** April 10, 2011, 05:39:02 PM »

Nice! What a great feeling. I hope the positive light continues to shine. I hope to one day see this beauty!

RAFster122s · « **Reply #436 on:** April 10, 2011, 05:42:00 PM »

May she be leak free... and trouble free for a long time.

David

luceja · « **Reply #437 on:** April 10, 2011, 06:46:33 PM »

Quote from: paulages on April 10, 2011, 05:12:53 PM

Ladies and gentlemen, we have a runner. No apparent oil leaks yet...

Super rad. I gotta get myself over there to see that thing all together. Congrats.

paulages · « **Reply #438 on:** April 11, 2011, 11:54:38 AM »

Still keeping my fingers crossed. I took it for a test run last night, and left one of the valve cover bolts out (the rear on either side hold my fairing mounts), which spilled some oil. That aside, I'm very worried my old porous oil leak "friend" may be rearing it's head again. There was a bit of DARK oil on one of the front fins, where it leaked before I had the block sealed. I don't want to jump to any conclusions until I re-torque the head (went with the copper gasket again), but I can't figure out where else dirty oil would be coming from when it has fresh oil, and the whole thing was just washed and reassembled. I really hope it's just some old oil that was hiding off in the head/block somewhere that turned up once it saw heat and wind.

We'll see, I guess...

sinister902 · « **Reply #439 on:** April 11, 2011, 12:11:31 PM »

I love this build and the bike it's in. I hope this is the last of your issues paul, I have been searching for a 650 motor to go the exact same route as you.....your build is very inspiring.

paulages · « **Reply #440 on:** April 11, 2011, 04:27:51 PM »

Quote from: sinister902 on April 11, 2011, 12:11:31 PM

I love this build and the bike it's in. I hope this is the last of your issues paul, I have been searching for a 650 motor to go the exact same route as you.....your build is very inspiring.

Thanks!

I pressure washed the bike earlier, and got all between the fins and cylinders in case there was some old oil trapped in there somewhere. When I get the time, I'll re-torque the head and try again.

In other news, I seized up the engine in my KLX650-R last night at 80 MPH... for the second time this year. WTF?

RAFster122s · « **Reply #441 on:** April 11, 2011, 08:56:07 PM »

Quote from: paulages on April 11, 2011, 04:27:51 PM

Thanks!

I pressure washed the bike earlier, and got all between the fins and cylinders in case there was some old oil trapped in there somewhere. When I get the time, I'll re-torque the head and try again.

In other news, I seized up the engine in my KLX650-R last night at 80 MPH... for the second time this year. WTF?

OUCH! that must have been an exciting 80 to 0 unless your clutch was still functional.

What caused the first seizure? What did you do to rebuild it? Was it an oil starvation problem causing the seizure or heat? Is the KLX650-R water cooled?

Definitely a run of bad juju

David

paulages · « **Reply #442 on:** April 11, 2011, 10:52:58 PM »

Quote from: RAFster122S on April 11, 2011, 08:56:07 PM

Quote from: paulages on April 11, 2011, 04:27:51 PM

Thanks!

I pressure washed the bike earlier, and got all between the fins and cylinders in case there was some old oil trapped in there somewhere. When I get the time, I'll re-torque the head and try again.

In other news, I seized up the engine in my KLX650-R last night at 80 MPH... for the second time this year. WTF?

OUCH! that must have been an exciting 80 to 0 unless your clutch was still functional.

What caused the first seizure? What did you do to rebuild it? Was it an oil starvation problem causing the seizure or heat? Is the KLX650-R water cooled?

Definitely a run of bad juju

David

The KLX is water cooled. The first seizure happened also at 80mph, and locked the rear wheel up. It was an exhilarating 5 seconds feeling like I was dirtbiking keeping it upright, until my brain kicked in and pulled the clutch. That motor was a plugged oil passage between the intake and exhaust cams, absolutely DESTROYING the exhaust cam and journals. The intake side and everything else was totally normal. I haven't torn this one down, but it was a different engine so I'm praying for a piston seizure, so I can make one good engine out of the two. There aren't many KLXs in the states, so it makes finding parts difficult. Amazing bike though... fully adustable suspension with upside-down forks in the mid-90's? The torque is unreal... I had to learn to keep the front wheel down. Anyway...

paulages · « **Reply #443 on:** April 11, 2011, 10:54:20 PM »

Not the best audio, but Mark (Mlinder) filmed the first start up. I'll get a better video later where you can here the scream of the engine over the rattle of the tools on my lift..

CB735 first start up

RAFster122s · « **Reply #444 on:** April 11, 2011, 11:44:01 PM »

I hope the KLX motor can be rebuilt cheaply...sounds like a fun bike.
WOW! the CB735 sounds like a beast!

I'm eager to hear what my stock CB550K0 sounds like with the Jardine 4 into 2 pipes... Need to polish/clean them up and get them installed.
Going through things and cleaning up a bike that last ran in the mid-80s.

Good luck Paul with the KLX teardown and I hope the old oil was just some old oil hiding in the fins you missed from before.
Be careful out there...

David

mlinder · « **Reply #445 on:** April 12, 2011, 07:57:20 AM »

I was there. Awesome to see it running again. The audio is a bit weird, because everything in his work area was vibrating along with the bike.

paulages · « **Reply #446 on:** April 26, 2011, 11:22:31 AM »

Not that anyone's on the edge of their seats here or anything, but I haven't had the time to re-torque the head and shake it down some more, and I leave the country tomorrow afternoon for 6 weeks. Come June I'd better be riding this goddamn thing!

bwaller · « **Reply #447 on:** April 26, 2011, 05:39:46 PM »

Here's hoping you're past all the nonsense.

I think I've acquired some of your sh!t luck.

paulages · « **Reply #448 on:** April 28, 2011, 06:40:01 AM »

Quote from: bwaller on April 26, 2011, 05:39:46 PM

Here's hoping you're past all the nonsense.

I think I've acquired some of your sh!t luck.

Uh oh!! I sure hope not...

Ecosse · « **Reply #449 on:** May 01, 2011, 05:50:06 PM »

Quote from: paulages on April 26, 2011, 11:22:31 AM

Not that anyone's on the edge of their seats here or anything, but I haven't had the time to re-torque the head and shake it down some more, and I leave the country tomorrow afternoon for 6 weeks. Come June I'd better be riding this goddamn thing!

argh!!

News:

Author Topic: Rebirth of paulages' cb735 (Read 115500 times)