Author Topic: 79 CB 650 refurb turns resto / mod (Read 53325 times)

thrutheframe · « **on:** February 19, 2011, 03:47:38 AM »

I bought my 79 CB 650 off of Craigslist in December. My original idea was to buy a cheap bike to ride while I was restoring my KZ 1000. I saw her in the tiny photo and had to have her. I think its the fat tank and swept bars that make her so sexy. I had never owned a SOHC bike and was always a Kaw man until that day. I paid $600.00 plus $100.00 for delivery. I spent the first month working on my KZ resto and occasionally cleaning and repairing little items here and there on the 650. Then one day I ran out of money for the serious work of Kaw restoration and started really looking at my "insurance policy". Other than years of neglect related dirt and grime the first thing I noticed was a cracked coil. Well I just couldn't let that go and started looking for a set of coils. That led me here and all the cool tech data that everyone has been so kind as to post. A tiny spark grew in me. That spark, my OCD and a missing rear brake pedal mount on my KZ frame led me to the decision to sink a few hundred bucks into this thing so I could ride with pride and confidence. I will post new pics and my progress periodically. Here a few just to get started.

Scott

thrutheframe · « **Reply #1 on:** February 19, 2011, 04:02:43 AM »

I cut the airbox off the inner fender with a good old fashion sawzall. Then ground the whole mess down to a presentable form with a belt sander, my carpentry skills paid off here. In the next pic you can see the section of the airbox that I salvaged, the clip tray for the wire harness mounts to the top of the air box. This mod was much easier than the metal bracket that I was considering.

MoMo · « **Reply #2 on:** February 19, 2011, 05:15:49 AM »

Are you making a cafe style bike? I have a complete cb650 if you need any parts...Larry

thrutheframe · « **Reply #3 on:** February 19, 2011, 06:34:06 AM »

Larry, its a mostly stock bike. I pulled the air box to make room for the pod filters. My only non stock items will be the MAC 4 into 1 and the pod filters. I would like to build a cafe bike, where are you and what do you want for the bike?

Scott

thrutheframe · « **Reply #4 on:** February 19, 2011, 05:24:35 PM »

Tonight I got my Bronze bushings (CBX Performance) in my swing arm and a coat of primer on it. I have the rear fender, inner fender, battery box and the wire harness clip tray in place. I'm not sure if I'll have to pull those off as I go, I've never reassembled this much of a CB650 at once. I'm a little concerned about the wires coming from my ignition, they are roted across the bottom of my clutch cover and up the frame with my brake light switch. The brake light switch wiring is fine but the ignition system wiring is a bit close to the brake switch spring for my taste. Theres nothing to secure it to as it passes the motor mount and foot peg mount. Anyone have any input on where this is supposed to be routed?
Next week will be a big week, lots of parts coming in from all over.

I hope youre all well and rubber down.

SG

MoMo · « **Reply #5 on:** February 19, 2011, 05:35:10 PM »

Quote from: thrutheframe on February 19, 2011, 06:34:06 AM

Larry, its a mostly stock bike. I pulled the air box to make room for the pod filters. My only non stock items will be the MAC 4 into 1 and the pod filters. I would like to build a cafe bike, where are you and what do you want for the bike?

Scott

Near Philadelphia, PA...Most likely too far. Have fun with the build....Larry

thrutheframe · « **Reply #6 on:** February 21, 2011, 06:39:08 PM »

Today I spent about 4 hours working on my CB. I hand sawed the rear shock bushings out and resanded the entire swing arm back to bare metal. I didn't like the way the primer adhered. Simple wrenching and electrical stuff I do pretty quickly. Paint prep, I am slow as molasses, I would love to have a sand blasting cabinet but my space is rented and in an industrial building so I'm limited as to what I can do.

My fork springs, rear shocks/springs and carb jets all arrived today. UPS says "Brown can deliver on pointless holidays" I should have the rear end of this thing back together by Thursday latest.

Peace out SG

rickyracer · « **Reply #7 on:** February 22, 2011, 10:06:21 AM »

Great project!....im working on on a 79 650 too, but doing a cafe style, just finished painting frame and redoing new fork seals and dust covers. Working on painting front wheel and redoing the exhaust today.

thrutheframe · « **Reply #8 on:** February 22, 2011, 11:30:44 AM »

Any fork seal removal tips? I know that's the thing that will slow me down. I hope your project goes well.

Scott

rickyracer · « **Reply #9 on:** February 22, 2011, 07:52:29 PM »

Quote from: thrutheframe on February 22, 2011, 11:30:44 AM

Any fork seal removal tips? I know that's the thing that will slow me down. I hope your project goes well.

Scott

Hey Scott as a matter of fact the fork seals did not come out as easy as the manual stated lol...guess they wasnt thinking it would be 30+ yrs before they were replaced. They were tough but i dipped them in hot water for about 10min. added a little salt & pepper, no just kiddin on the S&P and it helped having the heat. I also use a old flathead chisel with rounded corners. I did have to lightly sand the edges after getting them out to smooth where the chisel left a couple marks. Putting the seals in was easy using a large socket and tapping them in with a mallet. My biggest challenge was removing one of the upper shock plug which was a 18mm allen bolt. One of them was stuck so hard i couldnt remove it and had to take it to a local shop, they charged me $20 dollars which wasnt bad and i was ready to get the sledge hammer arrrrr. Oh yea dont forget to put in new dust covers to, good luck bro i will put some pix up as soon as i can find a program to shrink them enough.

Rick

thrutheframe · « **Reply #10 on:** February 22, 2011, 09:10:32 PM »

Cool, thanks for the tip. Once I get to a place where I can upload some pics I'll post some shots from tonights adventure into cleaning up the rear portion of the wiring harness and finalizing my inner fender mod.

thrutheframe · « **Reply #11 on:** February 23, 2011, 05:36:18 AM »

Last night I cleaned up and re attached the rear part of my wire harness. The theme for last night was fun with heavy duty zip ties.
In the pic you can see I mounted my flashe relay using the original rubber ring and a zip tie.

thrutheframe · « **Reply #12 on:** February 23, 2011, 05:42:00 AM »

A top view. Im replacing 3 of these 4 connectors. I have new (eBay new) CDI igniton units coming, when they show up I'll bolt my REC/REG and be done under the seat for now.

thrutheframe · « **Reply #13 on:** February 23, 2011, 05:46:17 AM »

A better view of the 4 under seat electrical connections. Battery acid took its toll on alot of stuff under the seat and on the right side of this bike.

thrutheframe · « **Reply #14 on:** February 23, 2011, 05:50:31 AM »

I was concerned that my inner fender was going to vibrate or flop around at speed. The airbox gave it stability by attaching to the frame under the seat. The gap in the pic below has trouble written all over it.

thrutheframe · « **Reply #15 on:** February 23, 2011, 05:54:00 AM »

Back to the zip tie theme. I used a plunge cutting tip on my dremel and cut a slot in the fender so I could pass a heavy duty zip tie thru it and aronud the frame. It looks nice and neat and the head of the tie is tucked under the fender.

thrutheframe · « **Reply #16 on:** February 23, 2011, 05:57:17 AM »

Repeated the process on the right side, twice on this side though you cant see the top zip tie in this pic.

thrutheframe · « **Reply #17 on:** February 23, 2011, 06:01:26 AM »

My super sweet rear fender. A few minutes with a buffer and it would look show room new.

thrutheframe · « **Reply #18 on:** February 23, 2011, 06:08:55 AM »

Dry fitted my left side cover. I want to cut these back to the frame tube, paint them silver and put some decals on them. I have a cool random ones and zeroes graphic that I'm working on. Silver with black decal and white numbers.

thrutheframe · « **Reply #19 on:** February 23, 2011, 11:12:18 PM »

Yesterday I disassembled my starter relay and cleaned the grime out of it. I redid the inline fuse holder with the 30 amp fuse. The battery and starter cables are re-attached, I'm waiting on a rubber mount for the relay, the PO was using the wires to hold it onto the bike.

My painting isn't going so well on my swing arm. I had a nice automotive quality look going and I destroyed it by sanding out a tiny run and trying to repaint that section. The paint went all cracked looking on me as soon as I sprayed it on. I'll take a look at it tomorrow and decide what to do. I don't want to
spend the money on powder coat but I will if I have to.

rickyracer · « **Reply #20 on:** February 24, 2011, 08:21:20 AM »

Lol your side cover looks just like mine well most of the 650 side covers same color and condition too funny. On your swingarm painting I'm wondering what did you wipe it down with before you repainted it? I just painted my pipes yesterday up on the roof (its a flat roof) after sanding the old rust pitted chrome for 2 hrs. Working on sanding tank and side covers today...not working this week so lots of time to work on it. Nice watching your progress and nice job on the zip ties, keep posting!

thrutheframe · « **Reply #21 on:** February 25, 2011, 07:05:33 AM »

I sure contaminated it somehow. I hit the crinkled spots with sandpaper, 80 then 150 then 220 and hit the whole thing with 220 til it was dull and wiped it real good with a new shop rag. I put a coat on it yesterday about 3:30 and one this morning at 9:00 ish. Its looking pretty good but painting is not my strong point. I will post a couple of pics once I get it ready to bolt back on. I was hoping to be bolting the ass end back together by now but the painting thing killed my progress. Im waiting on my chain and sprockets too, hmmmm almost forgot about that stuff.

thrutheframe · « **Reply #22 on:** February 25, 2011, 07:16:21 AM »

I want to pull the head on my CB650. Its leaking oil at the head gasket or O-rings. I plan to pull the head, inspect it, inspect the tops of the pistons, replace the head gasket and O-rings and clean it up real good externally. I've never done this before so I'm looking for advice on how to proceed and what else I should plan to do to the head while I have it off. I have a Clymer Manual and time so I figure I can do about anything. I plan to get started with this part after I get the rear end of the chassis put back together, middle of next week.

Please help.

Scott

rickyracer · « **Reply #23 on:** February 25, 2011, 10:47:07 AM »

Yea not sure about what to look for with head off maybe vavle condition? Seems like we are both close to the same progress too funny. I'm going to attempt to install my engine myself today, but i need to connect a winch to my rafters to lift a lower down should be an experience! I just sanded and primed my side covers tank and tail yesterday on the roof (its flat) to take advantage of the full sun for drying, its raining today and tomorrow so they say. Its my first sandable primer coat so far. Good luck with the head removal hopefully you wont run into more issues. Here is a pic of it primed i just set the parts on to get a rough look.

thrutheframe · « **Reply #24 on:** February 26, 2011, 09:05:31 AM »

I put the last coat of paint on my swing arm this morning. I have a nice 1000w lightbulb I'm going to cure it under for a few days. I got a new oil pan in from eBay yesterday but I'm not really thrilled with it. One of the fins is broken off. Ill run it for now and look at getting the threads in my original redone. Its pretty easy to drop and swap the pan.

Not much activity lately, Ive literally been waiting on paint to dry. And for my chain, sprockets and shock bushings to show up. I hate to start pulling the head off until the ass end is back together. I don't have a ton of room for all the parts to lay around.

Peace,
SG

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Author Topic: 79 CB 650 refurb turns resto / mod (Read 53325 times)