Topic: fmctm1sw: 1981 CB650 custom AKA The Nifty 650

[fmctm1sw]

Well, a rinse with hot water after the xylene and one more soak with toilet bowl cleaner and water.  I used a vacuum brake bleeder to suck standing water off the bottom before I used a hair dryer to dry it.  Not real easy to see in photos but now its lined and I have a 4 day wait...

[fmctm1sw]

Whoo hoo, 4 days is up!  I kept it at the proper temperature by hiding it in the bedroom closet after the weather cooled off a couple days ago.  Can't believe I got away with that.  I should be in business after I get the other side of the exhaust.  A few observations about the POR-15.  I didn't have any Marine Clean or Metal Ready.  I used a combination of MEK/xylene, Simple Green, and Toilet bowl cleaner.  I had a gallon og muriatic acid that I never did use.  All adaed up though, the kit from POR-15 would probably have been cheaper but I didn't want to wait.  I had a can of tank sealer on my shelf.  Receipt said August 2009!  It was all separated so I mixed it up real good.  I thought about leaving it sit for a while but I didn't want it hardening up any.  It seemed to be thicker than the last can I had (possibly from sitting so long)and had tiny bubbles in it (probably from mixing it).  I'm glad I didn't wait because I really had to roll it around to get it all coated.  I had a few weak spots that I touched on the outside with the tank sealer.  I guess we'll see when I get gas in it.

[fmctm1sw]

I figured why waste a good tank job and not do the cap.  So here's the cap cleaned up.  That little ring comes off, could have saved me some frustration...   

[hoodellyhoo]

glad to hear the tank lining seems to have worked well. Sounds like you were very meticulous which seems to be the key to getting it to last a long time.

[fmctm1sw]

Got my exhaust yesterday.  It would be on the bike by now if it weren't for some serious plumbing issues right now.  They look pretty good, the seller cleaned them up pretty well before he listed them. 

[aaawwwyyeeaahh]

Well, Sunday was start up day.  Although I had it running before I considered this a "first run" since the actual gas tank is being used. Since I'm still waiting on my choke cable, I held the choke closed and it started after a few seconds.  Ok, problem number one.  Petcock leaks but thankfully only in the "on" position.  So I teaked on that for a little.  Started it up again and found it dies the minute you give it any throttle.  Also a little popping now and then.  The timing was good but I took it all apart anyway and cleaned the advance mechanism and points shaft.  After all that, I realized I never turned the fuel back on.  So...  got it going again, all pipes hot.  Running much better but I notied the small screw I used to plug the carb #2 connection (temporary I assure you) to the (removed) fuel pump was trying to spit the screw out.  Hmm, valves too tight?  I set it according to my manual and found all of them were tight.  Possibly from the PO tightening the lock nuts and having the adjuster turn with them?  Normally, when all of the valves don't seem right, it's just me doing something wrong.  Didn't seem like it this time though.  I'm certain I was at TDC compression stroke when I started (I watched the intake valve).  I don't know if I'm going to try running it again before I get the choke cable.  I did get a disk brake caliper as well that hopefully I can salvage the piston out of.

I'm also in the process of restoring a 1981 CB650c, your motorcycle is coming along a lot better/faster than mine.  I had my carbs rebuilt a few weeks ago and I've been looking for a new choke cable for the past two days. Would you mind telling me where you ordered yours from?

thanks

[nitroeagle]

to awwwyyyeaahh? I have an '82 650. I just goggled cb650 choke cable & started looking at sites. Of course I can't remember where it came from. Try dennis kirk, dime city cycles, jc whitney, & z1enterprises.

[fmctm1sw]

Quick update, been busy with other stuff.  My liner job failed.  I called POR-15 and asked what the shelf life of the sealant was.  He said 2 years at first, then told me as long as it was liquid and I mixed it up real well it should be ok.  Maybe, maybe not.  As mentioned in another post, the sealant seems real thick.  When I drained the excess, hardly any came out.  I had nearly half a can left over with my 350F.  I know the 650 tank is bigger but...  It also looks like it pooled real thick along on side.  I'm trying to get the liner out right now.  The good news is, I tweaked the mixture screws little and it runs much better.  I got down the road and back (with no tank and a hose and funnel attached to the carbs  ) without any hesitation.  AS soon as I can get this tank down, I figure I'll have a rider. 

For the choke cable question:  I looked all over for one that matched the exact part number.  The '81 650C choke cable was very specific (along with a bunch of other parts it seems).  Others may work but the only place I found an exact one was off a guy in Ireland that had a used one (ebay).

[aaawwwyyeeaahh]

 I'm still searching. I actually ordered one online last weekend but I got an email a couple days ago saying that the part was discontinued.

thanks


(I wasn't trying to hijack your thread.)

[fmctm1sw]

Update.  Here's the bike in it's current state.  I have the other tank off trying to de-rust it (in another thread).  I rode it to the end of the block twice.  Very strong.  My tach needle "mod" didn't work so I'll need another tach and then tires.  Probably a master cylinder too.

[fmctm1sw]

Here's another "current state."  I got a set of stock handlebars on it over the weekend.  I pretty much decided to give up on the blue tank.  I continued to break off little pieces of the liner but the bottoms front of the tank continued to weaken.  The only thing I can think of to save it is to cut it open, clean the old liner out and weld it back up and line it.  I have neither the instruments or skills to do that.  The tank on it is fine but unsightly.  After digging around on ebay for black side covers, it dawned on me to just paint mine black.  One black was too dull, the other too shiny to match the tank, but the tank needs work anyway.  Still have a few needs but I rode it around the block the other day.  Once I get my new tires, I'm going to clean the rims when I take the wheels off. 

*edit* seat cover on the way too...   Those emblems were "custom painted."  I soaked them in brush cleaner.  Now to look at some stock emblems and get them painted.

[onepieceatatime]

*edit* seat cover on the way too...   Those emblems were "custom painted."  I soaked them in brush cleaner.  Now to look at some stock emblems and get them painted.

My bike is an '80, but the tank and covers are '81 for color reference on the emblems.
Red inside the 650 and black around the edges.

[onepieceatatime]

So far, I reckon I need...  carb dissassembly and cleaning (one of the slides is frozen), new choke cable, ignition switch (or key), intake rubbers, and starter relay.  Oh, and tires when I get that far.  And brake work too...

Did you get a new key or ignition?

[fmctm1sw]

*edit* seat cover on the way too...   Those emblems were "custom painted."  I soaked them in brush cleaner.  Now to look at some stock emblems and get them painted.

My bike is an '80, but the tank and covers are '81 for color reference on the emblems.
Red inside the 650 and black around the edges.

That's funny, mine's an '81 with an '80 tank on it.  I just decided to paint the side covers black.  Thanks for the info, and yeah I got an ignition switch from another member a while back. 

[onepieceatatime]

That's funny, mine's an '81 with an '80 tank on it.  I just decided to paint the side covers black.  Thanks for the info, and yeah I got an ignition switch from another member a while back.

How did you match up the '80 fuel line to the '81 carbs?
PO replaced the petcock on mine with one that matched the '81 tank bung and '80 fuel line. It had a beat up nasty tank on it. I got that one off ebay.

[fmctm1sw]

That's funny, mine's an '81 with an '80 tank on it.  I just decided to paint the side covers black.  Thanks for the info, and yeah I got an ignition switch from another member a while back.

How did you match up the '80 fuel line to the '81 carbs?
PO replaced the petcock on mine with one that matched the '81 tank bung and '80 fuel line. It had a beat up nasty tank on it. I got that one off ebay.

I no longer have the vacuum petcock on it and my fuel line is ghetto.  I didn't realize when I bought the '80 tank that my '81 petcock wouldn't work.  I ended up scoring one for $10 off eBay.  I have line on it I bought from autozone (can't remember the ID).  As for the petcock, I fit a smaller ID line onto it and then pushed the larger line one over that one.  That's a temp idea until I figure something else out.  That line is kind of an oddball size, nothing from autozone seems to fit it properly.  I'll try to get a picture of it if I have time over the weekend.

[cb650]

You can get universal filters that will fit both sizes.  Got mine from auto zone.

[fmctm1sw]

I looked around at my local Autozone but didn't see any filters like cb650 mentioned.  I got my fork seals and some other stuff last week.  I had my new tires mounted today and figured I'd do the fork seals before I put the front tire on it. 

I read over the CB650 fork seal thread in the FAQ and it was moving smoothly...  too smoothly.  I wasn't wrenching on the correct places on the air hose but I eventually figured it out.  I took a picture of what you should wrench on.  I decided to do one fork at a time and tied the caliper to the other side and planned to switch when one fork leg was finished. 

Unfortunately, I never got that far.  When I popped the dust cover off and went to remove the retaining ring, the retaining ring fell apart into four pieces.  Another delay but I did get my seat cover put on and as said, the wheels are ready to go too.

Oh year, I decided to loosen the fork cap while it was still clamped by the pinch bolts.  That may help...

[fmctm1sw]

Here's more...

[cb650]

Dont have the package anymore but the filter was a clear plastic with 1/4 and 5/16 barbs at both ends. I'll post a pick of it tomorrow.

[onepieceatatime]

Unfortunately, I never got that far.  When I popped the dust cover off and went to remove the retaining ring, the retaining ring fell apart into four pieces.  Another delay but I did get my seat cover put on and as said, the wheels are ready to go too.

All 4 sets of forks I have taken apart the retaining ring was severely rusted and if there was anything solid left from them, it was in several pieces. At least they are available from the dealer and not expensive.

[fmctm1sw]

I got to work on the fork seals the other day.  I'm doing one at a time so the brake calipers can hang together on the other fork leg.  I followed the procedure in the FAQ.  I picked up a 4 foot bar clamp at Harbor Freight and fashioned a plug for the fork cap.  I filled the leg most of the way with ATF and put the cap on.  I squeezed it into the clamp and maxed the range of the clamp.  It sat for a bit and I started to worry but I soon heard a hissing sound.  Then a moment later I had a mess of ATF.  The only issue is that only one side of the seal came out, the other side is still stuck.  It seems like when I try to pry around, the opposite side sinks.  Next idea is the thread a screw into the low side and yank...

[JimJamerino]

Something that worked for me was to pull the lower leg off the tube and dunk the seal end in hot water.  I used the side burner on my grill to heat a pot of water and put the seal end in for a couple minutes at a time.  I then used a big screwdriver to pry and a few rags to protect the lip of the leg.  I had to be careful not to scratch the seal bed.  You can check my build thread in my sig line for pics.

[fmctm1sw]

Something that worked for me was to pull the lower leg off the tube and dunk the seal end in hot water.  I used the side burner on my grill to heat a pot of water and put the seal end in for a couple minutes at a time.  I then used a big screwdriver to pry and a few rags to protect the lip of the leg.  I had to be careful not to scratch the seal bed.  You can check my build thread in my sig line for pics.

I'm guessing you removed that allen bolt on the bottom huh?  That's what I was trying to avoid.

[JimJamerino]

I did.  I looked back over the thread, and I didn't see anywhere you mention not wanting to remove the lower leg.  Any particular reason for avoiding this?